English - Marzocchi
Contents
1. u S gt oOx t a ds A oa i o o L2 SS E 3 EE a D o wt a S Gs B T z Q S gt kd Q Y Y 130 Disk brake mounts XC International Standard for 6 disk V brake fit Drop out type Standard e QR20Plus O QR 20 With Bolt O Accessories Integrated fender current O option not available IN een Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009_1 Table 5 Street DJ TRAVEL C mm 80 A max mm 468 A min mm 388 9 ES 2 b 9 9 Disk brake mounts V brake fit e XC International Standard for 6 disk Drop out type Standard 20 mm dedicated axle QR 20 Plus QR 20 With Bolt Accessories Integrated fender current not available Technical information MZ009_1 O option N ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as in2. English Installation 3 6 Wheel installing with a 883 Series fork For correct fork function please follow the instructions here below when installing the wheel Insert the wheel axle A through the right wheel axle clamp the wheel and the left wheel axle clamp Lock and keep locking the wheel axle from the right side using a 6 mm Allen key then still using a 6 mm Allen key tighten the wheel axle up to the required torque see Table Tightening Torques acting on the cap C Fully compress the fork a few times to properly align the fork legs Using a 5 mm Allen key tighten to the required torque see Table Tightening Torques the bolts B positioned on both dropouts with the sequence 1 2 1 marzocchi MZ009031 MZ009032 MZ009033 MZ009_1 MZ009_1 3 7 Wheel installing with a Monster Series fork For a correct fork s function please follow the instructions here below when installing the wheel In case the fork has been disassembled from the bike frame or the fork s legs position as to the crowns has been changed you will have to slightly loose the 6 bolts E holding the arch D by means of a 4 mm Allen key Insert the wheel axle A through the right wheel axle clamp the wheel and the left wheel axle clamp By using a 6 mm Allen key tighten the axle bolt B located on the left side to the r
3. not available A ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information Technical information _ ______________marzocchi Table 10 Junior T amp Super T PRO TRAVEL C 170 A max 558 A min 388 Q tr a amp K EN EN Im 3 V x Y K u D S 3 2 gt 2 7 D Y Y Disk brake mounts XC International Standard for 6 disk V brake fit 7 Drop out type Standard e QR 20 Plus O O QR 20 With Bolt O e Accessories Integrated fender Direct mount handlebar clamp long or short current O option not available Junior T Super T PRO AN ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009_1 MZ009_1 Table 11 Shiver DC Technical information TRAVEL C mm 190 A max mm 572 A min mm 382 25 ry S E z Y Q Q g
4. DJ Urban Riding This BMX or motocross style riding is only for the most skilled riders and involves jumping from one mound of dirt to another It also includes riding over and around urban obstacles such as man made or other concrete structures These forks should be used only with disk brakes as well as frames wheels and other components specifically designed for this riding style The disk brakes must be attached to the designated mounting points provided on the fork Never make any modification to your fork to attach any equipment Down Hill DH Extreme Free Ride This discipline is only for professional or highly skilled riders It includes for relatively high jumps or drops and negotiating larger obstacles such as boulders fallen trees or holes These forks should be used only with disk brakes as well as frames wheels and other components specifically designed for this riding style The disk brakes must be attached to the designated mounting points provided on the fork Never make any modification to your fork to attach any equipment A WARNING Ride only in areas specifically designated for your riding style E marzocchi 2 Select the Correct Fork for Your Riding Style from the Table Below Please see your Marzocchi retailer or contact Marzocchi directly if you require assistance in selecting the correct fork Tab 1 2004 Fork Riding Categories and Intended USE XC Marathon
5. However no fork can withstand misuse abuse or improper use that over a short period of time can cause your forks to fail when you least expect it It is critical that you select and use the fork that is appropriate for your riding style and that you use the fork properly 1 Identify Your Riding Style Trekking Trekking is similar to XC riding but not as aggressive as XC t involves slower riding and no riding over obstacles such as rocks roots or depressions You should only attach generators and racks to the designated mounting points provided on the forks Never make any modification to your fork to attach any equipment Cross Country XC Marathon Riding along hilly trails where some bumps and smaller obstacles such as rocks roots or depressions may be encountered XC riding does not include jumps or drops riding off rocks fallen trees or ledges from any height XC forks must only be used with tires specifically designed for cross country riding or disk rim or linear pull brakes Eree Ride FR This riding style is for skilled riders and involves aggressive slopes large obstacles and moderate jumps Free Ride forks should be used only with disk brakes as well as frames wheels and other components specifically designed for Free Riding The disk brakes must be attached to the designated mounting points provided on the fork Never make any modification to your fork to attach any equipment Dirt Jumper
6. rate too stiff or fork oil too travel high Get softer spring Decrease air pressure Fork extends too Increase rebound damping quickly harsh top out Not enough rebound damping Replace oil SAE 7 5 with a higher after impacts S viscosity Fork gets easily to Not enough compression Increase compression damping at travel end damping travel end via the proper adjuster Front wheel wants to Decrease the rebound damping Too much rebound damping tuck under while spring rate too soft cornering Fork packs up or stays down in travel Increase spring rate during multiple Too much rebound damping Decrease rebound damping impacts Knocking sound during rebound but Too much rebound damping Decrease rebound damping no harsh top out Operations to be carried out at MARZOCCHI authorized centres SS Ki a E Maintenance marzocchi Problem Diagnosis Solution Oil ring on f c 9 Oil seals are contaminated N Replace all seals stanchions Heavy amount of oil on stanchions oil dripping down legs g Replace all seals and have the stanchions inspected Seals are damaged stanchions could be damaged Fork is sticky fork does not perform as new Oil seals are contaminated fork Ki Replace all seals needs to be serviced H Oil leakage from the bottom Loose bottom nut screw Tighten bottom nut screw O ring damaged a Replace O rin
7. the brake system manufacturer Improper installation can be dangerous for the rider Use only brake systems in accordance with the fork s specifications considering that All forks with 032mm legs can only mount disk brakes The forks with 030mm legs can be equipped before delivery with disk brake mounts or V brake mounts O AoA r Installation The transformation from one braking system to the other must be done by qualified personnel In the forks with assembled arch slider models for 29 wheel and Z1 Wedge bolts A are not only used to fix the V brake levers they also contribute to lock the upper part of the slider to the arch In the case of installation of a disk brake system the service centres can replace bolts A with screws B The user is not allowed to remove bolts A or screws B Do not replace screws B with commercial bolts On the thread of bolts A C and screws B a special anti unscrewing treatment has been applied as a result the removed bolts cannot be re used as they lose such treatment When a disk braking system is mounted before any use check that the brake tube is correctly fixed to the special mount D E a EJ S Q B m Ve d S Installation 3 3 Wheel installing with a standard fork s end N ATTENTION Install the wheel in compliance with the manufacturer s instructions For correct fork fun
8. 0With Bolt Accessories current O option not available A ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009_1 MZ009_1 Technical information Table 3 Marathon 29er Mx Series 29er TRAVEL C mm 85 100 A max mm 495 505 A min mm 410 410 Q9 Q x E EP S oy EN u E 2 N S S 8 D E Da y S N Y Y Disk brake mounts e XC International Standard for 6 disk V brake fit e Drop out type Standard e QR 20 Plus QR 20 With Bolt L3 Accessories current O option not available A ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information Technical information _______________marzocchi Table 4 Dirt Jumper Series TRAVEL C mm 110 130 150 A max mm 498 518 538 A min mm 388 388 388 only for Dirt Jumper Il
9. 4 By turning the knob counterclockwise to positions 2 3 4 you will get less rebound resistance accordingly Position 5 MINIMUM EXTENSION DAMPING When the knob is fully turned counterclockwise you will reach the position of minimum extension damping giving the fork the maximum response N ATTENTION Do not use the LOCK OUT n 1 position for any reason while riding hard downhill as the fork could not react safely enough when hitting obstacles 5 9 ETA The ETA cartridge offers on the fly adjustment of the rebound damping by reducing the fork s length while still maintaining 30 mm of travel By turning the small lever B clockwise you will activate the ETA cartridge function By turning the small lever B counterclockwise you will bring your fork to its normal function and the travel reducing device will be no longer be engaged AN reinen Do not use the ETA device for any reason while riding hard downhill as the fork could not react safely enough when hitting obstacles Adjustments MZ009018 MZ009019 MZ009020 kd E E S Em SS Tables marzocchi 6 TABLES Table 19 Tightening torques Components to be tightened Tightening Torque Nm Wheel axle bolts 15 1 Wheel axle allen bolts 10 1 Fork s upper caps all except 888 Series 20 1 Fork s up
10. Ey S L S marzoceni marzocchi General warnings for owners manual S AN WARNING Failure to follow these instructions could result in failure of the product an accident personal injury or death 1 USE OF THE MANUAL Carefully read follow and understand the instructions given in this manual It is an essential part of the product and you should keep it in a safe place for future reference If the use and maintenance instructions provided in this manual are not properly performed or if the other instructions in this manual are not followed an accident could occur resulting in an accident serious injury or death Please be advised that suspension system installation and repair requires specialized knowledge tools and experience General mechanical aptitude may not be sufficient to properly install or repair your suspension system Please have your suspension system installed and or serviced only by an authorized Marzocchi Service Center Never make any modification whatsoever to any component of your suspension system A GENERAL SAFETY RECOMMENDATIONS Be sure to use the correct suspension system for your style of riding Check the Intended Use Instructions in this manual Please note that there are inherent risks associated with downhill free ride cross country marathon trekking dirt jumping and urban style riding You could be seriously injured or killed while engaged i
11. Free Riding DJ Urban Riding DOWN HilExtreme Trekking Free Riding Z 150 Free Ride Z 150 FR SL Z 150 Drop Off l Marathon SL ZAFRSL S ad d Monster T TXC Marathon S Z 1 FR Dirt pee m Super Monster TXC ECC Z 1 Drop Off B Z 1 Drop Off II Z 1 Wedge MX Comp MX Pro Shiver SC Shiver SC Super T Pro MZ Comp e MZ Race Drop Off Comp Street DJ Junior T EXR Comp 888 R EXR Pro Drop Off Triple 888 RR EXR Supra 888 RT Shiver DC 3 Do Not Misuse or Abuse Your Forks Do not misuse or abuse your forks Learn how to ride and always ride within your abilities An out of control ride puts the equivalent of years of hard use on your forks after only a few rides Learn how to properly flow around obstacles on the trail Hitting obstacles such as rocks trees or holes straight on puts forces on your fork it was not designed to absorb Landing improperly after a jump or drop also puts forces on your fork it was not designed to absorb You should only perform jumps or drops when a transition or down ramp is available to help your bicycle absorb the impact forces generated during the landing and both wheels should smoothly make contact with the transition or down ramp at the same time Any other type of landing is dangerous as it could result in a component part failure and an accident The steepness and length of the transition or down ramp depends on the height from which you jump or drop Every situation is different for every rider consult wit
12. RES amp TIMMERMANS Lda Bike Center Condominio Industrial de Alcolombal Estrada de Alcolombal Armaz m 1 2705 833 TERRUGEM SINTRA Portugal Contact Hans Timmermans Tel 351 0 21 961 06 21 Fax 351 0 21 961 06 38 bkecenter mail telepac pt www bikecenter pt com SPAIN TEAM BIKE S L Elche Parque Industrial c Juan de la Cierva 87 03203 Torrellano Elche Alicante Spain Contact Simon Tel 34 965 68 35 34 Fax 34 965 68 05 10 Info teambike es SWEDEN AVENIX AB Importgatan 17 422 46 HISINGS BACKA Sweden Tel 46 0 31 52 20 00 Fax 46 0 31 52 20 10 Info derbysweden se www derbysweden se SWITZERLAND LIECHTENSTEIN INTERCYCLE Haldenmattstr 3 CH 6210 SURSEE Switzerland Tel 41 0 41 9266511 Fax 41 0 41 9266352 Info intercycle com www intercycle com THE NETHERLANDS LUXEMBURG AUGUSTA BENELUX BV Roosveltstraat 46 NL 2321 BM LEIDEN The Netherlands Contact Mr Koeman Tel 31 0 71 5791580 Fax 31 0 71 5323201 Marzocchi augustabenelux nl UNITED KINGDOM IRELAND SOLENT UK Ltd t a Windwave Unit 9 Clarence Wharf Industrial Estate Mumby Road GOSPORT Hants PO12 1AJ UK Tel 44 0 23 92521912 Fax 44 0 23 92522625 Ofice windwave co uk www windwave co uk x LA Marzocchi distributors and service centers marzocchi OTHER COUNTRIES COUNTRY COMPANY AUSTRALIA GROUPE SPORTIF PTY LTD 20 Hark
13. Suspension System is altered erased defaced or otherwise subject to any tampering PURCHASER This warranty is made by Marzocchi S p A with only the original purchaser of the Marzocchi Suspension System and does not extend to any third Warranty parties The rights of the original purchaser under this warranty may not be assigned TERM The term of this warranty shall commence on the date of purchase and shall continue for a period of two 2 years from the date of the original purchase PROCEDURE In event of a defect covered by this warranty the purchaser should contact an authorized Marzocchi dealer or a Marzocchi Service Centre for the USA Marzocchi USA ENTIRE AGREEMENT This warranty supersedes any and all oral or express warranties statements or undertakings that may previously have been made and contains the entire agreement between the parties with respect to the warranty of this Marzocchi Suspension System Any and all warranties not contained in this warranty are specifically excluded DAMAGES Except as expressiy provided by this warranty Marzocchi S p A SHALL NOT BE RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ASSOCIATED WITH THE USE OF THE MARZOCCHI SUSPENSION SYSTEM OR A CLAIM UNDER THIS AGREEMENT WHETHER THE CLAIM IS BASED ON CONTRACT TORT OR OTHERWISE The foregoing statements of warranty are exclusive and lieu of all other remedies Some states do not allow the exclusion or limitati
14. ading this manual please carefully read the information contained in the Safety regulations for the manual s user section The information contained in the Safety regulations for the manual s user section will have to be followed for both the MARZOCCHI BOMBER forks and maintenance If you have any questions regarding the care and maintenance of your suspension system please contact your nearest service center directly A list of service centers can be found at 1 1 Conventions 1 1 1 Orientation of the fork MZ009001 1 1 2 Editorial pictograms N ATTENTION marzocchi the end of this manual or on the Internet page www marzocchi com This manual does not explain how to assemble disassemble the fork from the bicycle the wheel the steering set or any other component directly or indirectly associated with the fork that are not actually a part of the fork MARZOCCHI reserves the right to make changes to the products at any time and without prior notice to improve the products or to meet any productive or commercial requirements The user is the only person responsible for the correct application of the assembly instructions in the present manual er NOTE Descriptions preceded by this symbol contain information instructions or procedures which if not respected can cause damage or bad function to the fork accidents to the user even fatal ones or damage to the env
15. adjustments table Fork PLe PLmi PLi A A REBC ECA EHSC PRe PRi ECC5 ETA Dirt Jumper I e e Dirt Jumper Il e e Dirt Jumper Ill e Junior T e e Marathon S Marathon SL Monster T CDR e MX Comp AIR MX Comp COIL MX Comp ETA MX Pro AIR MX Pro COIL x MX Pro ETA 888 R e e e 888 RR e e 888 RT Non adjustable model Shiver DC e e Shiver SC e e Street DJ e Super Monster e eo Super T PRO e Z1 Drop Off I e Z1 Drop Off Il e Z1 FR e e e 0 0 0o o Z1 FRSL Z 150 DO Z1 Wedge Z 150 FR eo Z 150 FR SL e e See paragraph The Mx Pro Coil model can be supplied with a PLe register or an A register MZ009 1 MZ009_1 Table 18 Legend Adjustments PLe External Preload Spring preload with external adjuster PLmi Internal mechanic Preload Spring preload with internal mechanical adjuster PLi Internal Preload Internal Preload At Positive Air Preload Positive Air Preload A Negative Air Preload Negative Air Preload REBC Rebound cartridge Rebound Cartridge ECA External Compression Adjust External Compression Adjust EHSC External High Speed Compression External High Speed Compression PRe External rebound register External rebound register PRi Internal rebound register Internal rebound register ECC5 Boston extension conia 5 positi
16. any overhead object such as a parking garage bridge tree limb or other abutment with your bicycle while your bicycle is attached to a bicycle carrier you can damage your forks Have your forks inspected by an authorized Marzocchi Service Center before you ride Always wear a properly fitted and fastened bicycle helmet that has been approved by ANSI or SNELL and any other safety equipment necessary for your riding style B BEFORE EVERY RIDE Check that none of the components to your suspension system or the remainder of your bicycle are bent deformed cracked or otherwise damaged Check to be sure that all quick release fasteners nuts and bolts are properly adjusted Bounce the bicycle on the ground and listen and look for anything which may be loose MZ009 1 MZ009_1 Be sure that your wheels are perfectly centered Spin the wheels to be sure that they do not wobble up and down or from side to side and that they do not make contact with the fork legs or brake pads while rotating Learn and follow the local bicycle laws and regulations and obey all traffic signals signs and laws while you ride DO NOT RIDE YOUR BICYCLE IF IT DOES NOT PASS THIS PRE RIDE TEST CORRECT ANY CONDITION BEFORE YOU RIDE INTENDED USE INSTRUCTIONS SELECT THE CORRECT FORK FOR YOUR RIDING STYLE AND RIDE PROPERLY Marzocchi suspension forks are among the most durable and technologically advanced forks on the market today
17. ase of this Marzocchi Suspension System If any defect covered under the warranty appears with the agreed terms send the Marzocchi Suspension System postage prepaid to an authorized dealer or to a Marzocchi Service Center for the USA Marzocchi USA including a copy of the invoice or the ticket When doing so please state your full name address date of purchase and explain the problem of defect The policy of Marzocchi S p A is to offer corteous and efficient service with respect to warranty claims Please take care of your Marzocchi Suspension System and in case you suspect it can be damaged please contact your dealer or a Marzocchi Service Center for the USA Marzocchi USA MARZOCCHI and BOMBER trademarks licensed by Marzocchi S p A MZ009_1 Notes NOTES ISHBUR SE V enz HEEN MARZOCCHI distributors and service centers Marzocchi distributors and service centers MARZOCCHI DISTRIBUTORS AND SERVICE CENTERS EUROPE COUNTRY COMPANY marzocchi AUSTRIA TRENDSPORT GmbH S dtirolerstr 1 A6911 LOCHAU Austria Contact Mr Klaus Froeis Tel 43 0 5574 47147 Fax 43 0 5574 52334 Info trendsport co at BELGIUM RAKBIKE S A Avenue Jeanne 13 1050 IXELLES Belgium Contact Rafi Kasparian Tel 32 012 6466682 Fax 32 012 6466682 Rakbike wanadoo be www rakbike nethings net DENMARK SCAN BIKE Frichsvej 17 DK 8600 SILKEBORG Denma
18. c valve pumping rods which operate according to compression speed Speed Sensitive Valving Pumping rods can be controlled by external or internal adjusters or they can have a fixed setting Cartridges and pumping rods are fully plunged in oil Open Bath System This system provides proper lubrication and cooling of the inner sliding parts furthermore the oil volume works as a damping and setting element The Open Bath system reduces the maintenance frequency compared to a sealed cartridge system Stanchion tubes are guided in the sliders by two teflon coated bushings free from static friction The seal system prevents oil leaks and contamination from particles entering the fork It uses a special dual lip oil seal and a dust seal at the top of each slider You will find here below the different fork damping systems ECC5 the new Extension Control Cartridge offers on the fly adjustment of the rebound damping with a 5 position clicker Use the fast rebound position for downhilling the 3 middle positions for race start sprints and rough climbing and the fully closed ECC position for steep dirt switchback climbs or Marathon style road climbs ETA the new Extension Travel Adjustment locks down the rebound damping like the standard ECC but still allows 25 30 mm of travel HSCV the High Speed Compression Valve HSCV allows lighter damping for better trail sensitivity but still resists bottoming It is the best mar
19. ch to reduce it L ATTENTION During the extraction and the insertion of the metallic wire be very careful not to damage the components If the pumping rod and more precisely the metallic wire are even slightly damaged do not use the fork in any case and immediately contact a Marzocchi authorized service centre Do not alter the metallic wire Lift the stanchions and tighten the fork s upper cap B using a 26 mm wrench up to the required torque see Table Tightening Torques VIN renne During the insertion of the cartridge inside the stanchion be very careful not to damage the O Ring D Adjustments MZ009029 MZ009030 CA English x vs a gt Adjustments 5 1 4 Air preload N ATTENTION To inflate your fork use only the special MARZOCCHI pump with pressure gauge which you can buy at the authorized centers Use of improper tools might lead to improper inflating and cause improper function or damage to the fork itself er NOTE If you need to reduce the pressure inside the fork s leg just push lightly on the valve pin by means of a pointed object Apply the same preload pressure on both legs By pressurizing air through the valve D you can adjust the damping of the forces generated during the COMPRESSION phase If you increase the pressure inside the fork s leg you increase the preload To do so you need to remov
20. ction after wheel installing you will need to check the correct fork wheel alignment by fully compressing the fork a few times lift the front wheel above the ground turn the wheel a few times to verify the correct alignment with the disk brake or the V brake pads 3 4 Wheel installing with a QR20 Plus fork For correct fork function please follow the instructions here below when installing the wheel Release the securing system on both legs by pushing the levers A downwards and open the flap P For quick release hubs open the release lever B For threaded cap hubs unscrew the cap C as much as needed to insert the wheel axle through the fork wheel axle clamp nsert the wheel axle D through the fork wheel axle clamp Make sure that the wheel axle supporting bushings E are centered in the sliders seat If the wheel axle is provided with quick release system lock the wheel with the quick release lever B otherwise tighten the cap positioned on the axle side using a 6 mm Allen key to the required tightening torque see Table Tightening Torques Verify the correct settling of the supporting bushings E Check the correct fork wheel alignment by fully compressing the fork a few times Lift the front wheel turn the wheel a few times to verify the correct alignment with the disk brake Lock the securing system by pulling the levers A upwards and adjust clearance thro
21. dicative Please check on the internet page www marzocchi com for updated information Technical information marzocchi Table 6 Z1 Wedge TRAVEL C mm 130 A max mm 503 A min mm 373 SS Ki a E Z1 Wedge 353 Max 340 130 e XC International Standard for 6 disk e Disk brake mounts V brake fit Drop out type Standard e QR20Plus m QR 20 With Bolt Accessories mi current O option not available IN een Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009_1 MZ009_1 Table 7 Z 1 Series TRAVEL C mm Technical information 130 A max mm 518 A min mm 388 Z1 Series except for Z1 Wedge 352 Max 345 130 Disk brake mounts e XC International Standard for 6 disk V brake fit Drop out type Standard e QR 20 Plus O QR 20 With Bolt O Accessories Integrated tender AN eune current O option not available Marzocchi reserves the right to modify data and features quoted in the table he
22. e the dust cap A fully tighten the threaded pump adapter inflate air up to the required pressure refit the dust cap A Some forks are provided with a more sophisticated adjustment system and a different air valve in this case to adjust the air preload you will need the supplied dedicated adapter Right leg positive air adjustment Using a 2mm Allen wrench loosen the screw C fixing the ECC5 knob Pay attention that pin L and spring H do not come out of their seat Remove screw C and knob B Fit and tighten the adapter of the inflation pump E to the valve Inflate till reaching the pressure you wish Refit the knob B Using the 2mm Allen wrench tighten the screw C to the recommended torque see table Tightening Torques marzocchi MZ009015 MZ009022 MZ009023 MZ009 1 MZ009_1 Left leg positive air adjustment Unscrew and remove the dust cap A Fully tighten the pump adapter on the outside valve B Inflate air up to the required pressure Fully tighten the dust cap A AS ASTENT R Respect the suggested pressures Spring forks see Table Recommended pressures for spring forks Air forks see Table Recommended pressures for air forks 5 2 Negative air AN ganeu To inflate your fork use only the special MARZOCCHI pump with pressure gauge which you can buy a
23. ension System by an authorized Marzocchi dealer for the USA Marzocchi USA freight prepaid together with the original retail invoice or other evidence of the date of purchase 1 NOT COVERED This warranty does not cover damage resulting from accidents alteration neglect misuse abuse or improper use lack of reasonable or proper maintenance improper assembly repairs improperly performed or replacement parts or accessories not conforming to Marzocchi S p A s specifications modifications not recommended or approved in writing by Marzocchi S p A activities such as acrobatics stunt jumping ramp riding racing commercial use and or normal wear or deterioration occasioned by the use of the suspension system Items subject to normal wear or deterioration include but are not limited to oil dust seals oil seals and bushings In addition this warranty is void in the event that the forks are used with any rental bicycles unless Marzocchi S p A provided prior approval in writing for such use This warranty also does not include any expenses related to the transportation of the Marzocchi Suspension System to or from an authorized Marzocchi dealer for the USA Marzocchi USA labor costs to remove the Marzocchi Suspension System from the bicycle or compensation for inconvenience or loss of use while the Marzocchi Suspension System is being repaired This warranty will be automatically void if serial number of the Marzocchi
24. equired torque see Table Tightening Torques Fully compress the fork a few times By using the 5 mm Allen key tighten the bolts C positioned on both dropouts to the required torque see Table Tightening Torques with the 1 2 1 sequence By using the 4 mm Allen key tighten the bolts E with the sequence 1 2 3 2 1 to the required torque see Table Tightening Torques AS reuneg An incorrect wheel alignment can lead to loss of proper legs sliding Installation MZ002019 English L a MZ002005 MZ002007 MZ002006 FR vs a gt Installation 3 8 Wheel installing with a Shiver fork For correct fork function please follow the instructions here below when installing the wheel Insert the wheel axle A through the right wheel axle clamp the wheel and the left wheel axle clamp Screw down the bolt B on the left side and tighten to the required torque see Table Tightening Torques Fully compress the fork a few times to properly align the fork legs Tighten to the required torque see Table Tightening Torques the bolts C positioned on both dropouts with the sequence 1 2 1 3 9 Fender installing The 32 mm legs forks and the 888 Series forks can be equipped with an integrated fender The fender can be provided with the fork or purchased separately When assembling the fender F you mus
25. er Street BURWOOD Victoria 3125 Australia Tel 61 3 9888 9882 Fax 61 3 9888 9902 hel roupesportif com www groupesportif com BRAZIL PLINIO CURI IMP EXP LTDS Rwa Pamplona 8185 Andar 01405 030 SAO PAOLO Brasil Tel 55 11 2510633 Fax 55 11 2515069 pcuri ibm net CANADA NORCO PRODUCTS LTD 1465 Kebet Way PORT COQUITLAM B C V3C 6L3 Canada Tel 1 604 552 2930 Fax 1 604 552 2948 Sales norco com www norco com PHILIPPINES FAREN ENTERPRISES 59_E Bansalangin St Project 7 1105 Quezon City Philippines Tel 632 372 2541 Fax 632 372 2311 hansgee mydestiny net ISRAEL CYCLE TRADING COMPANY LTD Hapardes Rd RISHPON Israel Tel 972 9 9513010 Fax 972 9 9509783 sales ctc co il e www ctc co il KOREA FOURS 69 6 Jeongja Dong Bundang Gu Seongnam Si KYONGGI DO Korea Tel 82 0 31 719 6520 21 Fax 82 0 31 719 6519 Fours1 yahoo co kr SINGAPORE CAPPA TRADING PTE LTD 85 Kaki Bukit Avenue Shun Li Industrial Park SINGAPORE 417955 Singapore Tel 65 8415151 Fax 65 8425133 cappa pacific net sg OFFICIAL DISTRIBUTOR ALSO FOR MALAYSIA INDONESIA BRUNEI THAILAND USA SOUTH AMERICA MARZOCCHI USA 25213 Anza Drive VALENCIA CA 91355 USA Tel 1 661 257 6630 Fax 1 661 257 6636 Marzmail marzocchiusa com www marzocchi com MZ009_1
26. g Loss of sensitivity Worn sliding bushings Ji Replace sliding bushings Old oil Change oil A Operations to be carried out at MARZOCCHI authorized Centres Table 16 Periodical maintenance table Use General maintenance operation Intense Normal Check screws tightening up Before every ride to required torque Clean the sliders After every ride Air pressure control Before every ride 10 hours Check the oil seals x 25 hours 50 hours Oil change 50 hours 100 hours Oil seals replacement x 50 hours 100 hours S Operations to be carried out at MARZOCCHI authorized centres MZ009_1 MZ009_1 4 2 General safety regulations After a complete breakdown always use new original Marzocchi seals when reassembling To tighten two bolts or nuts that are near each other always follow the sequence 1 2 1 using the required tightening torque see Table Tightening Torques Never use flammable or corrosive solvents to clean the parts as these could damage the seals If necessary use specific detergents that are not corrosive not flammable or have a high flash point compatible with the seals materials and preferably biodegradable If you are planning not to use your fork for a long time always lubricate the forks components that are in contact with some fork s oil Never pour lubricants solvents or detergents which are not completely biodegradable in the environment these m
27. h an experienced rider before attempting any jump or drop AN WARNING Failure to properly flow around obstacles on the trail or failure to properly land after a jump or drop could cause your forks to fail resulting in a loss of bicycle control and serious injury or death to the rider Your forks require regular maintenance and repair The harder you ride the more often you must inspect and maintain your forks If your forks are bent deformed cracked or chipped no matter how slight immediately have a Certified Marzocchi Repair Center inspect the forks before you ride again MZ009_1 MZ009_1 er REMEMBER Even forks made out of solid metal will fail if they are misused abused or improperly used Extreme use can eventually wear out and break even the strongest components Ride fast yet ride Smart MZ009_1 Use and maintenance instruction manual a S T Contents CONTENTS 1 Introduction General Safety Regulations suse 98 1 4 Conventions eese 98 1 1 1 Orientation of the fork 98 1 1 2 Editorial pictograms 98 1 2 Use application of the BOMBER Mel 99 2 Technical information 100 2 14 Fork s external components 100 is ZAA lt Ts sese 100 E 2 1 2 Legs protections 100 T 2 1 3 Wheel axle securing system 101 I 2 2 Fork interna
28. idge ETA cartridge Z 150 FR SL ECC5 hydraulic cartridge Negative air cartridge F A compression braking F R rebound or extension braking a S Q 5 SS T a E Installation 3 INSTALLATION 3 1 Installing on the frame The fork is supplied with A Head Set threadless steer tube to be cut according to frame size it will be used on Installing the fork on the bicycle frame is a very delicate operation that must be carried out by specialized personnel N ATTENTION The assembling on the frame and the steer tube adjustment must be carried out in compliance with the manufacturer s instructions Improper installation may jeopardize the safety of the rider Marzocchi does not guarantee the installation and refuses all responsibility for damages and or accidents that may be caused by an incorrect installation The steer tube must be pressed into the crown its replacement must be carried out by one of our service centers only using the required tools N ATTENTION In case of improper installation of the steer tube into the crown the rider might lose control of his her bicycle thus jeopardizing his her safety N ATTENTION On all dual crown MY 2004 BOMBER models the lower crown is clamped to the stanchions or to the sliders in the upside down models through some bolts In this case you will have to respect following precautions during installing n case of o
29. ironment Descriptions preceded by this symbol contain information prescriptions or procedures recommended by MARZOCCHI for the best fork s use MZ009_1 MZ009_1 Introduction General Safety Regulations 1 2 Use application of the BOMBER forks PP A ATTENTION Do not use forks for an application that is You will find in the following table the use different from the one provided by the applications of MY2004 Marzocchi Bomber manufacturer For further information forks concerning the specific fork s use please refer to the Safety regulations for the user Table 1 Use application of the MY 2004 BOMBER FORKS MARATHON DIRT JUMPER DOWN HILL CROSS COUNTRY EREERIDE URBAN FREE RIDE EXTREME Dirt Jumper Dee 6 Dirt Jumper Il e Dirt Jumper III oe Junior T E ol Marathon S Marathon SL Monster T MX Comp AIR MX Comp COIL MX Comp ETA MX Pro AIR MX Pro COIL MX Pro ETA 888 R 888 RR 888 RT Shiver DC Shiver SC Street DJ Super Monster Super T PRO Z1 Drop Off I Z1 Drop Off Il Z1 Wedge Z1 FR Z1FRSL Z 150 DO Z 150 FR Z 150 FR SL E S m ES Kel gt Technical information 2 TECHNICAL INFORMATION 2 1 Fork s external components The MY 2004 MARZOCCHI BOMBER forks range includes many different models having from 30 to 40 mm legs diameter and travels u
30. justable pumping rod SSV pumping rod with internal MX Comp COIL SSV pumping rod with internal adjustment adjustment MX Comp ETA SSV pumping rod with internal adjustment ETA Cartridge MX Pro AIR SSVF pumping rod with external adjustment Non adjustable pumping rod MX Pro COIL SSVF pumping rod with external adjustment Non adjustable pumping rod MX Pro ETA SSVF pumping rod with external adjustment ETA cartridge 888 R HSCV F R hydraulic cartridge Finali E en 888 RR HSCV F R hydraulic cartridge eur eT pumping 888 RT SSVF non adjustable pumping rod SMF Da Tain Shiver DC HSCV F R hydraulic cartridge HSCV F R hydraulic cartridge Shiver SC HSCV F R hydraulic cartridge HSCV F R hydraulic cartridge Street DJ SSV non adjustable pumping rod SSV non adjustable pumping rod Super Monster F R adjustment cartridge inthe upper area Final F A external adjustment and F A in the lower area cartridge Super T PRO HSCV F R hydraulic cartridge HSCV F R hydraulic cartridge Z1 Drop Off SSVF pumping rod with external adjustment ETA cartridge Z1 Drop Off II SSV pumping rod with external adjustment Non adjustable pumping rod Z1 Wedge SSV non adjustable pumping rod SSV non adjustable pumping rod Z1 FR HSCV F R hydraulic cartridge ETA cartridge Z1 FR SL ECC5 hydraulic cartridge Negative air cartridge Z 150 DO SSVF pumping rod with external adjustment ETA cartridge Z 150 FR HSCV F R hydraulic cartr
31. l components and D fork s operation o n 114 3 Installation ees 116 3 1 Installing on the frame 116 3 2 Installing the brake system 117 3 3 Wheel installing with a standard ele EE 118 3 4 Wheel installing with a QR20 Elek rar 118 3 5 Wheel installing with a QR20 With Bolt tork eee ee eee 119 3 6 Wheel installing with a 888 Series AON vic nennen genen 120 3 7 Wheel installing with a Monster Series fork T 121 3 8 Wheel installing with a Shiver fork 122 3 9 Fender installing 122 4 Maintenance 123 4 1 Problems Diagnosis Solutions 123 4 2 General safety regulations 125 4 3 Cleaning the fork legs 126 4 4 Air Bleeding 127 marzocchi 5 Adjustments 128 5 1 jPreload aisneteet me 129 5 1 1 Spring preload with external adjustment 129 5 1 2 Spring preload with internal adjustment 130 5 1 3 Internal spring preload 131 5 1 4 Air preload sse 132 5 2 Negative air 133 5 3 Cartridge forks rebound adjustment nmn 134 5 4 Rebound adjustment with external adjustable pumping rod 135 5 5 Rebound adjustment with internal adjustable pumping rod 5 6 Compression adjustment 5 7 Compression adj
32. n rod B into the stanchion tube making sure to center the adjustment seat C When turning the adjuster counterclockwise you will increase the rebound hydraulic damping making the fork slower during the rebound phase When turning the adjuster clockwise you will decrease the rebound hydraulic damping making the fork more responsive during the rebound phase AN amento Do not force the adjustment screw C past its limits Adjustments MZ009036 MZ009016 MZ009017 E E LO 5 Ke vs a gt Adjustments 5 6 Compression adjustment By acting on the adjustment screw T located on bottom of the right leg you can control the fork s compression damping By turning the adjustment screw and using a proper small flat tip screwdriver you can adjust the hydraulic configuration of the inner valves that control the compression When turning the adjuster clockwise you will increase the compression hydraulic braking reducing the travel made by the fork under the same stress When turning the adjuster counter clockwise you will decrease the compression hydraulic braking making the fork softer against ground harshness N ATTENTION Do not force the adjuster screw T past its limits 5 7 Compression adjustment at bottoming The compression damping adjustment can be made according to the models by rotating
33. n those riding styles Learn how to ride never ride beyond your capabilities be sure to use the proper safety equipment and be sure that all your riding equipment is in excellent condition The lifespan of Marzocchi products depends on many factors such as riding style and riding conditions Impacts falls improper use or harsh use in general may compromise the structural integrity of the suspension system and significantly reduce its lifespan Please have your bicycle regularly inspected by a qualified mechanic for any oil leaks cracks deformation or other signs of fatigue The frequency of inspection depends on many factors check with your authorized Marzocchi representative to select a schedule that is best for you If the inspection reveals any deformation cracks impact marks stress marks or bent parts no matter how slight immediately have a Certified Marzocchi Repair Center inspect the forks before you ride again When installing or removing your bicycle from a bicycle carrier roof rack or rear hitch mount be sure that you fully loosen the quick release fastener on the carrier In addition be sure that your bicycle is lifted from or installed on the carrier in a perfectly vertical direction If the quick release fastener is not fully loosened or if there is any bending action while installing or removing your bicycle you will scratch bend or otherwise damage your suspension system If you strike at any speed
34. on extension control cartridge cartridge ETA Extension travel adjustment Extension travel adjustment cartridge cartridge 5 1 Preload To make the most of the fork s travel the sag given by the rider s weight must remain between 10 and 20 of the total travel length for the XC forks and between 20 and 30 for the DH forks To reach this result act on the spring preload adjusters or change the pressure in the fork legs 5 1 1 Spring preload with external adjustment er NOTE The fork is set to the minimum preload by the manufacturer i e the adjuster knob screw is completely turned counterclockwise However the spring is slightly preloaded to help counteractining static load By turning the knob A on the top of the fork s leg you can modify the spring preload to adjust the initial setting according to the rider s weight and needs By turning the knob clockwise the preload spring can be increased up to the maximum value which corresponds to a spring compression of about 15 mm By turning the knob counterclockwise you will reduce the preload spring down to the minimum value MZ009012 AN ATTENTION Do not force the adjustment knob past its limits A E E 5 SS S de a E Adjustments 5 1 2 Spring preload with internal adjustment er NOTE The fork is set to the minimum preload by the manufacturer i e the adjuster is completely t
35. on of incidental or consequential damages so this limitation or exclusion may not apply to you DISCLAIMER ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL IMPLIED WARRANTIES ARISING FROM A COURSE OF DEALING USAGE OF TRADE BY STATUTE OR OTHERWISE IS HEREBY STRICTLY LIMITED TO THE TERM OF THIS WRITTEN WARRANTY This Agreement shall be the sole and exclusive remedy available to the Purchaser with respect to this purchase In the event of any alleged breach of any warranty or any legal action brought by the purchaser based E E 7 m ES Kel gt Warranty 10 on alleged negligence or other tortious conduct by Marzocchi S p A the Purchaser s sole and exclusive remedy will be repair or replacement of defective materials as stated above No dealer and no other agent or employee of Marzocchi S p A is authorized to modify extend or enlarge this warranty WARNING Always install repair and use your Marzocchi Suspension System in strict compliance with its owner s manual OTHER RIGHTS This warranty gives you the specific legal rights and you have also other rights which vary from state to state USA only APPLICABLE LAW Any disputes arising out of this agreement or the use of this Marzocchi Suspension System will be governed by the laws of the country of Italy and will be decided by the Courts of Bologna Italy marzocchi er NOTE Thank you for the purch
36. p to 300 mm Apart from a few exceptions the MY 2004 MARZOCCHI BOMBER forks range consists of two main assemblies e the stanchion tubes steering crown assembly which are assembled through a cryogenic process called cryofit for a stiff and undetachable fit the magnesium casted sliders arch monolith assembly The materials used for the main components are the BAM aluminium from the aerospace industry and the magnesium these are lightweight materials that help reduce the fork s weight marzocchi 2 1 1 Fender MARZOCCHI offers an optional integrated fender for all models with 832mm legs and for the new forks of the 888 series The fender mounted to the underside of the crown helps protecting the rider against debris from the front tire 2 1 2 Legs protections They are made of plastic material and are current equipment on the upside down models Shiver SC and Shiver DC they allow legs protection from mud and dust that can be raised by the front wheel during use they also assure the legs integrity from hits MZ009 1 MZ009_1 2 1 3 Wheel axle securing system The system for securing the wheel axle to the fork sliders can be standard with traditional advanced dropouts or with the QR20 Plus system Forks using this system must have a suitable hub with 110 mm width spacing and a 20 mm wheel axle The MARZOCCHI QR20 Plus system it is the new sophisticated version of the QR20 system that fully wrap
37. per caps 888 Series 15 1 Upper crown fixing bolts 6 1 Lower crown fixing bolts 6 1 Fender fixing bolts 6 1 Handlebar clamp fixing bolts all dual crown forks except 888 Series 10 1 Handlebar clamp fixing bolts 888 Series 6 1 by ECC5 and ETA knobs fixing bolts 2 0 5 a Pumping rods and cartridges fixing foot nuts 111 Cartridges fixing foot nuts 25 1 Cantilever bolts fixing screws 1141 Pumping rods knobs fixing screws with lower external adjustment 2 0 5 Preload knobs fixing pins 1 5 0 5 Air bleed screw 3 0 5 Arch bolts Monster series 6 1 Table 20 Recommended positive air pressure for spring forks Positive air pressure 0 15 psi 0 1 bar Table 21 Recommended positive air pressure for air forks Rider s weight Positive air pressure 120 155 Ibs 55 70 kg 30 40 psi 2 0 2 75 bar 155 180 Ibs 70 80 kg 35 45 psi 2 40 3 10 bar 180 210 Ibs 80 95 kg 42 52 psi 2 90 3 80 bar 210 220 Ibs 95 100 kg 52 65 psi 3 60 4 5 bar Table 22 Recommended negative air pressure Negative air pressure 0 150 psi 0 10 3 bar MZ009_1 MZ009_1 7 WARRANTY If any component of your Marzocchi Suspension System is found to be defective in materials or workmanship within the term of this Limited Two Year Warranty the Agreement the defective component will be repaired or replaced at the option of Marzocchi S p A free of charge within thirty 30 days after receipt of the Susp
38. ponents E E ES 4 Ki a E Maintenance 4 3 Cleaning the fork legs er NOTE The manufacturer lubricates the fork dust seal with some grease which makes the stanchion tubes slide easier especially when the fork has not been used for a long time When using the suspension system such grease can melt and stick to the stanchions looking like an oil leak although it is not Clean using specific biodegradable not corrosive and not flammable detergents After every use carefully clean the fork paying special attention to the stanchion tubes and the dust seals AN ATTENTION Mud and dust if not eliminated immediately may cause serious damage to the suspension system In the Bomber forks except for the 830mm model it is also possible to clean the seat of the dust seal as described below N ATTENTION Do not clean the seat of the dust seal on the 930mm model With a small screwdriver prize the dust seal B off the slider C without scratching the stanchion tube Slide the dust seal along the stanchion tube and clean inside the dust seal and its seat on the slider with a jet of compressed air er NOTE It is advisable to tilt the fork leg to make it easier to remove foreign matters AN decent Never use metal tools to clean any particles of dirt Compress the fork legs slightly and remove any traces of dirt from the stanchion tubes mar
39. rawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009 1 MZ009_1 Table 13 Monster Series Technical information TRAVEL C mm 200 Monster 300 Super Monster A max mm 593 693 A min mm 393 393 225 8 E 030 i D g 40 o Max 73 Y u T G o 9 E Q gt 5 e S Y 110 175 Disk brake mounts DH International Standard for 8 disk Rear calliper mount V brake fit Drop out type Standard 20 mm dedicated axle QR 20 Plus QR 20 With Bolt Accessories Direct mount handlebar clamp long or short AN eune current O option not available Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information a EJ S Q 5 m aR Kel gt Technical information 2 2 Fork s internal components and fork s operation Inside MARZOCCHI forks you will find coil springs or air as a spring system The damping load that is generated during the fork legs compression and rebound can be adjusted by cartridges controlled by external adjusters or by special hydrauli
40. re above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information English M Technical information marzocchi Table 8 Z 150 Series TRAVEL C mm 150 A max mm 538 A min mm 388 m G vo i D E EI x YW S ly N wo E D Y Y 130 Disk brake mounts e XC International Standard for 6 disk V brake fit Drop out type Standard e QR20Plus O QR 20 With Bolt O Accessories Integrated fender current O option not available AN amento Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information MZ009_1 MZ009_1 Technical information Table 9 Shiver SC TRAVEL C mm 100 A max mm 482 A min mm 382 187 Q S Q i 5 2 gt HI i 3 S 135 Disk brake mounts XC International Standard for 6 disk V brake fit ES Drop out type Standard e G 20 mm dedicated axle QR 20 Plus QR 20 With Bolt Accessories current O option
41. rease the rebound hydraulic damping making the fork return slower during the rebound phase When turning the adjuster counterclockwise you will decrease the rebound hydraulic damping making the fork more responsive during the rebound phase N ATTENTION Do not force the adjustment screws A B past their limits marzocchi MZ009021 MZ009 1 MZ009_1 5 4 Rebound adjustment with external adjustable pumping rod When turning the adjustment knob B located on the bottom of the fork s leg you can adjust the damping during the rebound phase By turning on the adjustment screw you can modify the hydraulic configuration of the inner valves this means that there will be more or less oil flowing through the valve When turning the adjuster clockwise you will increase the rebound hydraulic damping making the fork slower during the rebound phase When turning the adjuster counterclockwise you will decrease the rebound hydraulic damping making the fork more responsive during the rebound phase A eune Do not force the adjustment knob B past its limits 5 5 Rebound adjustment with internal adjustable pumping rod You will find some damping rods where the rebound adjustment is located inside the stanchion tube To adjust these forks you will need to remove the dust cap A located on the top of the fork s leg insert the supplied hexago
42. rk Contact Lars Munsk Tel 45 0 86 80 54 88 Fax 45 0 86 80 54 75 scan bike email dk FINLAND OY DUELL BIKE CENTER AB Juhanilantie 4a 01740 VANTAA Finland Contact Jussi Laurikainen Tel 358 0 6 322 7500 Fax 358 0 6 322 2231 info duellbike fi e www duellbike fi FRANCE PHILAMY S A 1384 Parc Industriel Saint Maurice F 04100 Manosque France Contact Derrick Coetzer Tel 33 0 4 92 70 97 00 Fax 33 0 4 92 72 60 70 Info philamy com www philamy com GERMANY COSMIC SPORTS GmbH Ipsheimerstr 15 17 D 90431 N RNBERG Germany Tel 49 911 31 07 55 0 Fax 49 911 3107 55 55 Info cosmicsports de e www cosmicsports de ITALY LARM SPA Via C dell Orbo 36 40055 Villanova di Castenaso BOLOGNA Italy Tel 39 0516053460 Fax 39 0516053411 Sales larm it OFFICIAL DISTRIBUTOR ALSO FOR ALBANIA TURKEY GREECE BOSNIA HERZEGOVINA CROATIA YUGOSLAVIA SLOVENIA MACEDONIAN BULGARIA HUNGARY ROMANIA POLAND CZECH REPUBLIC SLOVAKIA MOLDAVIA UKRAINE BELARUS LITHUANIA LITTON ESTONIA RUSSIA ASIA OCEANIA JAPAN SOUTH AFRICA NORWAY SPORTPARTNER AS POSTBOKS 555 BERGEN 5884 Norway Tel 47 55 50 6464 Fax 47 55 50 6465 post sportpartner no www sportpartner no LA o0 N MZ009_1 MZ009_1 PORTUGAL Marzocchi distributors and service centers TAVA
43. s the 20 mm wheel axle for maximum stiffness while still providing an easy way to remove the wheel The new QR20 Plus 20 mm axle system is Technical information available in two different versions both using a forged aluminium hinge that is attached to the lower magnesium slider The forged aluminium lever can be the quick release one which makes opening and closing the flap routine or it can be with bolt where the clamping is made via a screw tightening The 20 mm wheel axle used in both QR20 Plus Systems can be the quick release type or the bolt on type The upside down forks Shiver SC and Shiver DC as well as the models created for more intensive use 888 Series and Monster Series are provided with a wheel fastening system originating from the motorcycle application using a 20 mm axle Marzocchi Bomber wheel axle securing systems A traditional advanced dropout B QR20 Plus C QR20 With Bolt D Shiver dedicated axle E Monster dedicated axle F 888 dedicated axle English 5 SS Ki a E Technical information ______________marzocchi Table 2 Marathon Mx Series TRAVEL C A max A min only for MX Comp Marathon amp Mx Series 353 Max 340 Disk brake mounts XC International Standard for 6 disk V brake fit Drop out type Standard QR 20 Plus QR2
44. t lt LU Ui H S Disk brake mounts e XC International Standard for 6 disk V brake fit Drop out type Standard G 20 mm dedicated axle QR 20 Plus QR 20 With Bolt Accessories Direct mount handlebar clamp long or short AN eune current O option not available Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information a EJ S K 5 SS Ki a E Technical information Table 12 888 Series marzocchi AN uaan TRAVEL C A max A min o o pu D Max 73 Q9 E ES e E IK N i E S 1 eel 110 145 Disk brake mounts XC International Standard for 6 disk V brake fit Drop out type Standard e 20 mm dedicated axle QR 20 Plus QR 20 With Bolt m Accessories Direct mount handlebar clamp Integrated fender current O option not available Marzocchi reserves the right to modify data and features quoted in the table here above if needed for technical and or commercial requirements The dimensions indicated in the d
45. t insert the small support bushing H between the screw and the fender as shown in the picture and tighten the screws G with a 8 mm Allen wrench to the required torque see Table Tightening Torques marzocchi MZ001021 MZ001022 a D IS lo lo IN Z MZ001023 MZ009_1 MZ009_1 Maintenance 4 MAINTENANCE 4 1 Problems Diagnosis Solutions This paragraph indicates some of the problems that may arise during the fork s use as well as the possible causes of these problems and the suggested solutions Always check this table before working on the fork Table 15 Problems Diagnosis Solutions Problem Diagnosis Solution Add spring preload by replacing the preload tube Fork has too much Spring rate too soft or fork oil too sag fluid SR Check the oil height a Change to stiffer spring rate a EJ S Q Increase air pressure Increase compression damping by Not enough compression changing oil level damping Increase compression damping through the proper adjuster Forks bottoms too easily but it has the recommended sag N U Fork bottoms too easily needs more than maximum preload to attain proper sag Increase air pressure Check oil height Spring rate too soft or fork oil too fluid Get stiffer springs KR Check oil height Fork does not get full Spring
46. t the authorized centers Use of improper tools might lead to improper inflating and cause improper function or damage to the fork itself By pressurizing air through the valve you can adjust the damping of the forces generated during the REBOUND phase If you increase the pressure inside the fork s leg you increase the rebound damping To do so you need to unscrew and remove the dust cap A fully tighten the pump adapter on the valve C that is located in the central position inflate air up to the required pressure fully tighten the dust cap A Adjustments MZ009024 MZ009025 MZ009026 English H w Uo Ke vs a gt Adjustments 5 3 Cartridge forks rebound adjustment The extension or rebound damping adjustment can be made according to the models by rotating the adjustment knob A directly or where the knob is not available by acting on the adjustment screw B using a proper flat tip screwdriver In both cases you will modify the hydraulic configuration of the inner valves regulating the rebound er NOTE On the models provided with compression hydraulic damping adjustment at travel end the rebound damping adjuster located on the top of the right leg can be easily recognized thanks to the R carved on the knob or on the cap When turning the adjuster clockwise you will inc
47. the adjustment knob A directly or where the knob is not available by acting on the adjustment screw B using a proper flat tip screwdriver In both cases you will modify the hydraulic configuration of the inner valves regulating the rebound er NOTE The compression damping adjuster at bottoming can be easily recognized thanks to the C carved on the knob or on the cap When turning the adjuster clockwise you will increase the hydraulic braking preventing the fork to bottom out When turning the adjuster counter clockwise you will decrease the hydraulic braking ZN ATTENTION Do not force the adjustment screws A B past their limits marzocchi MZ009037 MZ009035 MZ009 1 MZ009_1 5 8 ECC5 The ECC5 cartridge offers on the fly adjustment of the rebound damping By turning on the adjuster A you can modify the hydraulic configuration of the inner valves controlling the flow of more or less oil up to the LOCK OUT position where no oil flows through Adjustment is possible through a 5 position clicker Position 1 LOCK OUT When the knob is fully tightened clockwise you will get the maximum rebound damping In this position the fork s legs will stay down after impacts any other impact will make lower the fork s geometry further This position is only suitable for hard steep climbs Position 2 3
48. ugh the adjusters H if needed marzocchi Gel X d A TZS d 112001057 S E SY Le L MZ001038 MZ009_1 MZ009_1 3 5 Wheel installing with a QR20 With Bolt fork For correct fork function please follow the instructions here below when installing the wheel Using a 6 mm Allen key unscrew both screws L as much as needed to open the securing device M For quick release hubs open the release lever B For threaded cap hubs unscrew the cap C as much as needed to insert the wheel axle through the fork wheel axle clamp Insert the wheel axle D through the fork wheel axle clamp Make sure that the wheel axle supporting bushings E are centred in the sliders seat f the wheel axle is provided with quick release system lock the wheel with the quick release lever B otherwise tighten the cap positioned on the axle side using a 6 mm Allen key to the required tightening torque see Table Tightening Torques Verify the correct settling of the supporting bushings E Check the correct fork wheel alignment by fully compressing the fork a few times Lift the front wheel turn the wheel a few times to verify the correct alignment with the disk brake Lock the wheel axle securing device M and tighten both screws L using a 6 mm Allen key Installation MZ009010 MZ009011
49. urned counterclockwise However the spring is slightly preloaded to help counteractining static load To adjust the initial setting according to the rider s weight and needs you will have to remove the plastic protection cap A and turn the adjuster B using a 4 mm Allen key Byturning the adjsuter clockwise the preload spring can be increased up to the maximum value By turning the adjuster counterclockwise you will reduce the preload spring down to the minimum value Once the adjustment completed put the plastic protection cap A back to its seat N ATTENTION Do not force the adjuster past its limits B marzocchi MZ010012 N T MZ009034 Es 4mm MZ009_1 MZ009_1 5 1 3 Internal spring preload The 888R and 888RR models have a revolutionary coil preload system The spring preload adjustment must be carried out in respect of the procedure here below explained Using a 26 mm wrench unscrew both fork s upper caps A Lower the stanchions as much as needed to allow the shaft to come out the cartridge Press and keep pressing downwards the washer B supporting the spring Using a small screwdriver take off from its seat the metallic wire C that is locking the washer B supporting the spring Keep the washer pressed and insert the metallic wire into a lower notch to increase preload or into an upper not
50. ust be collected and kept in the relevant special containers then disposed of according to the regulations in force Use only metric spanners not imperial spanners which may have similar sizes but can damage the bolts and make it impossible to unscrew them Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws When using a screwdriver to assemble or disassemble metal stop rings o rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Do not carry out any maintenance and or adjustment operations that are not explained in this manual if necessary have such operations carried out by an authorized service centre Only proceed to Maintenance maintenance overhaul operations if you are sure you are able to do it and you have got the right tools If this is not the case or if you are unsure please contact an authorized service center where specialized technicians with the right tools and original spare parts will service and overhaul your fork putting it back into its original working conditions Only use original spare parts Work in a clean ordered and well lit place if possible avoid servicing outdoors Polished surfaces need to be periodically treated with some polishing compound to be kept as bright as new Carefully check there are no metal shavings or dust in the work area Do not modify the fork s com
51. ustment at bottoming sense 136 58 EG eain 137 9 9 EETA a een 137 6 Tables eese 138 Z UO aT T 139 N Le re 141 Marzocchi distributors and service Lo T T CH 281 MZ009_1 MZ009_1 TABLE INDEX Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Use application of the MY 2004 BOMBER FORKS 99 Marathon Mx Series 102 Dirt Jumper Series 104 Street DJ nts 105 Z1 Wedge EEN 106 Z 1 Series 107 Z 150 Series 108 ShiVer SC arenas 109 Junior T amp Super T PRO 110 Shiver DOC 111 888 Series 112 Monster Series 113 BOMBER forks damping Systems ienien inetr tde 115 Problems Diagnosis Solutions 123 Periodical maintenance table 124 MY04 adjustments table 128 Legend 129 Tightening torques 138 Recommended positive air pressure for spring forks 138 Recommended positive air pressure for air forks 138 Recommended negative air Sl reo eren 138 a EJ S EN SS S de a E Introduction General Safety Regulations 1 INTRODUCTION GENERAL SAFETY REGULATIONS Before re
52. versized diameter areas on the stanchions or on the sliders the crowns clamping can only be done in these areas as shown in the picture In case of reference notches on the stanchions or on the sliders the lower part of the lower crown must be positioned over the notch With the fork fully compressed the distance between the inflated tyre and the marzocchi MZ002011 bottom face of the steering crown shall be greater than 4 mm On the Monster forks the distance between the lower part of the lower crown and the dust seal must be bigger than 4 mm In the dual crown models the maximum length of the steering tube between the two crowns shall be less than the values indicated in the following table 888 160 mm Junior T e Super T PRO 184 mm Shiver DC with standard steering 445 mm crown Shiver DC with high steering crown 163 mm Monster Series 190 mm MZ009 1 MZ009_1 3 2 Installing the brake system Installing the brake system is a very delicate operation that must be carried out by specialized personnel AN reiten Marzocchi does not guarantee the installation and accepts no liability for damage and or accidents arising from a wrong installation Improper installation of the disk brake system can overstress the caliper mountings which may break The installation of the brake system must be carried out following the instructions of
53. zocchi MZ001002 MZ001003 Lubricate the dust seal and the visible surfaces of the oil seal with silicone grease Re assemble the dust seal B in its seat on the stanchion tube pressing it home with your hands MZ009_1 MZ009_1 4 4 Air Bleeding er NOTE This operation must be carried out with the fork assembled on the bicycle and with the fork s legs fully extended front wheel off the ground er NOTE Maintenance The pressure generated by the air that can get into the fork legs while the bike is being used and which due to the special shape of the oil seals remains trapped inside can cause the fork to malfunction In case of malfunction or loss of legs smoothness please carry out following operation on both legs By means of a 2 mm Allen key unscrew the air bleed screw A located on the cap in order to drain the pressure generated inside the fork s leg Check the oil seal B condition replace if needed Tighten the air bleed screw A to the recommended torque see Table Tightening Torques being careful not to damage the oil seal B MZ002013 a X EJ S Q S ds a E Adiusmens marzocchi 5 ADJUSTMENTS AX arenon Please visit our web site www marzocchi com for any information concerning the travel increase kit and for different spring rates K Table 17 MY04
54. zocchi way to provide a controlled damping environment for consistent and perfect damping The moving valve on the shaft controls rebound and low speed compression damping The special valve in the bottom of the cartridge HSCV takes the edge of any hard hit to maintain control SSV the Speed Sensitive Valve SSV uses 5 valve circuits to control damping rates based on the fork s compression and rebound speed as well as the fork s position in the travel SSVF The latest version of our Speed Sensitive Valve has a new Floating valve and spring design It incorporates a spring loaded valve which is more responsive and uses an external rebound adjuster MZ009_1 o 8 S N Technical information Table 14 BOMBER forks damping systems D Fork amping system Right leg Left leg Dirt Jumper I SSV pumping rod with external adjustment SSV non adjustable pumping rod Dirt Jumper Il SSV pumping rod with internal adjustment SSV non adjustable pumping rod Dirt Jumper III SSV non adjustable pumping rod SSV non adjustable pumping rod Junior T SSV non adjustable pumping rod SSV non adjustable pumping rod Marathon S HSCV F R hydraulic cartridge ETA cartridge Marathon SL ECC5 hydraulic cartridge Negative air cartridge F R adjustment cartridge in the upper area Final F A external adjustment Monster T and F A in the lower area cartridge MX Comp AIR SSV pumping rod with internal adjustment Non ad
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