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Marzocchi Bomber 2004, Owner'S Manual

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Marzocchi Bomber 2004 Owner'S Manual Download Page 29

Installation

M

Z

009_1

English

3

117

3.2 Installing the brake system

Installing the brake system is a very delicate
operation that must be carried out by
specialized personnel.

ATTENTION

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 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 ø32mm legs can only mount

disk brakes.

• The forks with ø30mm legs can be

equipped before delivery with disk brake
mounts or V-brake mounts.  

• 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

B

A

B

C

D

E

Summary of Contents for Bomber 2004

Page 1: ...MODEL YEAR 2004 ...

Page 2: ......

Page 3: ...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...

Page 4: ... 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 Free 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 Ridin...

Page 5: ...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...

Page 6: ..._1 11 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 ...

Page 7: ...MZ009_1 Use and maintenance instruction manual English ...

Page 8: ...a 888 Series fork 120 3 7 Wheel installing with a Monster Series fork 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 5 Adjustments 128 5 1 Preload 129 5 1 1 Spring preload with external adjustment 129 5 1 2 Spring preload with inte...

Page 9: ...er SC 109 Table 10 Junior T Super T PRO 110 Table 11 Shiver DC 111 Table 12 888 Series 112 Table 13 Monster Series 113 Table 14 BOMBER forks damping systems 115 Table 15 Problems Diagnosis Solutions 123 Table 16 Periodical maintenance table 124 Table 17 MY04 adjustments table 128 Table 18 Legend 129 Table 19 Tightening torques 138 Table 20 Recommended positive air pressure for spring forks 138 Tab...

Page 10: ...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 in...

Page 11: ...rning the specific fork s use please refer to the Safety regulations for the user Table 1 Use application of the MY 2004 BOMBER FORKS Dirt Jumper I Dirt Jumper II Dirt Jumper III Junior T Shiver DC Shiver SC Monster T 888 R 888 RR Super Monster Street DJ Super T PRO Marathon S Marathon SL MX Comp AIR MX Comp COIL MX Comp ETA MX Pro AIR MX Pro COIL 888 RT MX Pro ETA Z1 Drop Off II Z1 Wedge Z1 Drop ...

Page 12: ...onolith 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 2 1 1 Fender MARZOCCHI offers an optional integrated fender for all models with ø32mm legs and for the new forks of the 888 series The fender mounted to the underside of the crown helps protecting the ride...

Page 13: ...ns 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 an...

Page 14: ...ed in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 177 ø 30 80 100 130 18 ø 30 248 A C Max 340 353 Max 60 only for MX Comp A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Marathon Mx Series current option not availabl...

Page 15: ...s The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 175 ø 30 80 100 130 18 ø 30 283 A C Max 380 387 Max 60 A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Marathon 29er Mx 29er current option no...

Page 16: ...cative Please check on the internet page www marzocchi com for updated information 110 with QR20 Drop out 181 Max 68 ø 30 100 130 18 ø 32 A C Max 345 352 100 only for Dirt Jumper II A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Integrated fender Dirt Jumper Series DIrt Jumper I DIrt Jum...

Page 17: ... indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 177 80 110 130 25 ø 32 A C 320 ø 30 223 315 Max 65 mm mm mm Street DJ 468 388 80 Integrated fender A max A min TRAVEL C Disk brake mounts Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Ø 20 mm dedicated axle current o...

Page 18: ...nts The dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 175 ø 30 80 100 130 18 ø 30 248 A C Max 340 353 Max 60 mm mm mm Z1 Wedge 503 373 130 A max A min TRAVEL C Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk current option n...

Page 19: ...d in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 181 Max 68 ø 30 100 130 18 ø 32 A C Max 345 352 110 with QR20 Drop out A max A min TRAVEL C mm mm mm Disk brake mounts Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk current option not available 518 388 130 Z1 Series except fo...

Page 20: ...s indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information 181 Max 68 ø 30 100 130 18 ø 32 A C Max 345 352 110 with QR20 Drop out A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Integrated fender Z150 Series current ...

Page 21: ...e dimensions indicated in the drawing are only given as indicative Please check on the internet page www marzocchi com for updated information ø 30 Max 68 Max 345 187 112 135 C ø 30 A 15 A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Ø 20 mm dedicated axle Shiver SC current option not av...

Page 22: ...given as indicative Please check on the internet page www marzocchi com for updated information 110 with QR20 Drop outs ø 32 C 100 130 ø 30 Max 345 352 181 Max 68 18 A Max 184 A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Junior T Super T PRO current option not available 558 388 170 Int...

Page 23: ...wing are only given as indicative Please check on the internet page www marzocchi com for updated information 110 208 ø 30 C A Max 145 25 Max 68 Max 345 163 with high crown ø 35 A max A min TRAVEL C mm mm mm Disk brake mounts Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Ø 20 mm dedicated axle Direct mount handlebar clamp long or short Shiver DC...

Page 24: ...ing are only given as indicative Please check on the internet page www marzocchi com for updated information A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories XC International Standard for 6 disk Ø 20 mm dedicated axle Direct mount handlebar clamp Integrated fender 888 Series current option not available 575 405 170 605 405 20...

Page 25: ... as indicative Please check on the internet page www marzocchi com for updated information ø 30 225 34 ø 40 110 175 Max 73 Max 357 A C Max 190 A max A min TRAVEL C mm mm mm Disk brake mounts V brake fit Drop out type Standard QR 20 Plus QR 20 With Bolt Accessories DH International Standard for 8 disk Rear calliper mount Monster Series current option not available 593 393 200 Monster 693 393 300 Su...

Page 26: ... 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 ...

Page 27: ...ro 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 Final F A HSCV hydraulic cartridge 888 RR HSCV F R hydraulic cartridge SSVF non adjustable pumping rod 888 RT SSVF non adjustable pumping rod SSVF non adjustable pumping rod Shiver DC HSCV F R hydraulic cartridge HSCV F R...

Page 28: ...cycle thus jeopardizing his her safety 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 In case of oversized diameter areas on the stanchions or on the sliders the crowns clamping can only be done in these areas a...

Page 29: ...nt disk brakes The forks with ø30mm legs can be equipped before delivery with disk brake mounts or V brake mounts 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...

Page 30: ...e 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 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 th...

Page 31: ...ke sure that the wheel axle supporting bushings E are centred 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 f...

Page 32: ... 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 dropo...

Page 33: ...eel 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 required 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 ti...

Page 34: ...ly 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 Ø 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 must insert the small support bushing H bet...

Page 35: ...e than maximum preload to attain proper sag Spring rate too soft or fork oil too fluid Check oil height Get stiffer springs Increase air pressure Fork does not get full travel Spring rate too stiff or fork oil too high Check oil height Get softer spring Decrease air pressure Fork extends too quickly harsh top out after impacts Not enough rebound damping Increase rebound damping Replace oil SAE 7 5...

Page 36: ...chions inspected Fork is sticky fork does not perform as new Oil seals are contaminated fork needs to be serviced Replace all seals Oil leakage from the bottom Loose bottom nut screw Tighten bottom nut screw O ring damaged Replace O ring Loss of sensitivity Worn sliding bushings Replace sliding bushings Old oil Change oil General maintenance operation Use Intense Normal Check screws tightening up ...

Page 37: ... 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 n...

Page 38: ...Bomber forks except for the ø30mm model it is also possible to clean the seat of the dust seal as described below ATTENTION Do not clean the seat of the dust seal on the ø30mm 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...

Page 39: ...ecial 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 sc...

Page 40: ... or an A register Dirt Jumper I Dirt Jumper II Dirt Jumper III Junior T Shiver DC Shiver SC Monster T 888 R 888 RT Super Monster Street DJ Super T PRO Marathon S Marathon SL MX Comp AIR MX Comp COIL MX Comp ETA MX Pro AIR MX Pro COIL MX Pro ETA Z1 Drop Off II Z1 Drop Off I Z1 Wedge Z 150 DO Z 150 FR Z1 FR Z1 FR SL Z 150 FR SL 5 1 2 5 1 1 See paragraph 5 1 3 5 1 4 5 2 5 3 5 6 5 7 5 4 5 5 5 8 5 9 88...

Page 41: ...f 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 NOTE The fork is set to the minimum preload by the manufacturer i e the adjuster knob sc...

Page 42: ...d 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 By turning 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 ...

Page 43: ...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 notch to reduce it 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 c...

Page 44: ...hase If you increase the pressure inside the fork s leg you increase the preload To do so you need to remove 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 adapt...

Page 45: ...ON 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 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...

Page 46: ...d 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 increase the rebound hydraulic damping making the fork return slower during the rebound phase When turning the adjuster counte...

Page 47: ...d hydraulic damping making the fork more responsive during the rebound phase ATTENTION 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...

Page 48: ...k softer against ground harshness 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 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 c...

Page 49: ...d 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 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...

Page 50: ...g bolts all dual crown forks except 888 Series 10 1 Handlebar clamp fixing bolts 888 Series 6 1 ECC5 and ETA knobs fixing bolts 2 0 5 Pumping rods and cartridges fixing foot nuts 11 1 Cartridges fixing foot nuts 25 1 Cantilever bolts fixing screws 11 1 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 se...

Page 51: ...ANTY 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 Suspension System by an authorized Marzocchi dealer for the USA Marzocchi USA fre...

Page 52: ...ion System will be governed by the laws of the country of Italy and will be decided by the Courts of Bologna Italy NOTE Thank you for the purchase 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 ...

Page 53: ...Notes MZ009_1 English 141 NOTES N ...

Page 54: ...MZ009_1 281 MARZOCCHI distributors and service centers ...

Page 55: ...6 322 2231 info duellbike fi 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 NÜRNBERG Germany Tel 49 911 31 07 55 0 Fax 49 911 3107 55 55 Info cosmicsports de www cosmicsports de ITALY LARM SPA Vi...

Page 56: ...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 ...

Page 57: ...RISES 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 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 TRA...

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