Marzocchi Bomber Super Fly z.2 Instruction Manual Download | Manualshive

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N

CE 1949

SINCE 1949

SINCE 1949

F I F T Y Y E A R S O F

S U S

P E N S I O

N I N N O VAT IO

N

F I F T Y Y E A R S O F

S U S

P E N S I O

N I N N O VAT IO

N

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2
3
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Summary of Contents for Bomber Super Fly z.2

Page 1: ...CE 1949 SINCE 1949 SINCE 1949 FI F T Y Y E A R S OF S US PEN S I O N I N N O VATI O N FI F T Y Y E A R S OF S US PEN S I O N I N N O VATI O N ...

Page 2: ...justed at the time the Marzocchi suspension system was installed on the bicycle Before you ride the bicycle be sure all the parts of the bicycle were properly adjusted and functioning properly 3 All of the components of the suspension system must be correctly assembled and tightened exactly to the specified torque values Periodically check the torque of these components to insure that they are cor...

Page 3: ...ing complete stiction free performance Fork leg oil type EBH 16 SAE 7 5 50 c c each leg Lubrication oil 7 c c each leg BAM Bomber Aerospace Material Special alloy developed from aerospace material Size stroke 65 mm 2 5 inches crown to axle length 433 2 mm stanchions outer diameter 30 mm fork leg distance between centers 130 mm cantilever boss distance between centers 80 mm pilot bushing length 92 ...

Page 4: ...ion tube is scored 3 Excessive dirt on slider oil seal Excessive oil build up on slider Fork rebounds too fast even though the adjuster is on the max damping position 1 Piston ring s damaged 2 Seal pack at the bottom of the stanchion damaged 1 Change piston ring s 2 Change seals Excessive play of stanchions in the sliders Pilot bushing worn out Replace bushings Fork rebounds too fast in any adjust...

Page 5: ...might lose control of his her bicycle thus jeopardizing his her safety Check the torque of the bolts fastening the stanchions to the crown and attaching the arch to the sliders For recommended torque settings see the table below Tightening torque Thread diameter Nm lb ft M4 4 2 9 M5 9 6 6 M6 11 7 5 To remove the fork legs from the crown loosen the bolts 39 FIG A andremovethesafetyring 1 FIG A Fore...

Page 6: ...age 15 These operations refer to the fork legs having already been removed from the crown and disassembled from the brake arch Before starting any operation please read the diagram below It shows the quickest procedure and the exact sequence in which it should be disassembled Locate the part you need to remove in the diagram then look at the arrows to determine which other parts you will need to r...

Page 7: ...he fork leg Pump the stanchion several times to help oil drain off WARNING Remember to always recycle any used oil To change the fork leg oil follow the procedure as described in section REASSEMBLY from FIG 30 to FIG 32 FIG 3 Turntheslideroverandholditsteadywithyourhands Unscrewthefoot nut 18 with a 10 mm socket wrench Should this operation be difficult counteract by inserting an 8 mm Allen wrench...

Page 8: ...ings on the stop ring and carefully lifting the ring out of place IMPORTANT make sure not to damage the slider seat when removing the stop ring FIG 7 Fit the slider protector A onto the slider and remove the oil seal 7 with the help of a large slot screwdriver IMPORTANT when removing the oil seal make sure not to damage its seat Once removed the oil seals should not be used again FIG 8 Remove the ...

Page 9: ...complete with O ring 21 from the pumping rod 30 top Make sure the adjuster 19 is properly tightened on the inner rod top 34 If not unscrew the adjuster and spread a medium strong glue to avoid it gets loose during use FIG 11 Remove the stop ring 22 from the stanchion tube bottom 4 with bit pincers FIG 12 Push with a rubber drift inserted from the stanchion top and remove the pumping rod 30 with re...

Page 10: ...mping rod thread so not to damage seal pack 24 Pull out the seal pack 24 complete with seals upper washer 27 and rebound spring 29 from the pumping rod FIG 15 Remove the upper and lower Parker seals 25 from the seal pack 24 with a small screwdriver IMPORTANT once removed Parker seals should not be used again AIR VALVE DISASSEMBLY FIG 16 In case of pressure drops remove the air valve 16 and its OR ...

Page 11: ... the pilot bushing 9 into place so that it adheres to the slider FIG 18 Fit the upper washer 8 into the slider so that it touches the pilot bushing FIG 19 Lubricate the oil seal 7 and place it onto the seal press B with the hollow side toward the slider Press the oil seal into place until it touches the lower washer by using the above seal press FIG 20 Insert the stop ring 6 making sure it is prop...

Page 12: ...ings with your fingers SEAL PACK FIG 23 Insert the lower Parker seal 25 with the hollow side downward into the pack 24 from the OR seat side Fit the upper Parker seal 25 with the hollow side upward Fit the OR 23 duly greased in the pack outer seat FIG 24 Screw the driver C on the pumping rod Insert the rebound spring 29 the upper washer 27 and the seal pack 24 with the OR 23 side toward the inside...

Page 13: ...nchion Insert the stanchion tube 4 gently into the dust seal Rotate the stanchion tube while inserting it into the seal to facilitate installation and reduce the chance of damaging the seals Push the stanchion into the slider until the rod end comes out from the slider hole FIG 28 Turn the leg upside down and inject 77 c c of lubrication oil between pumping rod end and slider with a syringe Then p...

Page 14: ...maged HOW TO FILL WITH OIL FIG 30 Unscrew the adjuster 19 to the min position and then pour 50 c c of oil little by little and pump the stanchion to facilitate filling FIG 31 Lubricate the OR 3 on the cap 2 Lift the stanchion 4 and fit the cap 2 by hand FIG 32 Placethestanchioninavice Placethestanchiontubeinavice Besure it is not damaged or dented in the process and tighten the cap at 12 Nm Pressu...

Page 15: ... O ring 18 Foot nut 19 Adjuster 20 Retainer cup 21 O ring 22 Safety ring 23 O ring 24 Seal pack 25 Parker seal 26 Bushing 27 Washer 28 Safety ring 29 Rebound spring 30 Pumping rod 31 O Ring 32 Lower seal ring 33 Upper seal ring 34 Rod 35 O ring 36 L H sticker 37 R H sticker 38 Crown and steer tube 39 Screw 40 Sticker 37 36 28 27 25 25 24 23 22 20 21 27 26 18 16 5 4 6 7 8 9 10 18 15 29 31 19 4 33 3...

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