Marzocchi Shiver DC 2005 Technical Instructions Download | Manualshive

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2005 - Shiver DC

Technical instructions

© Marzocchi Suspension

2005

-

Shiver DC

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Summary of Contents for Shiver DC 2005

Page 1: ...2005 Shiver DC Technical instructions Marzocchi Suspension 2005 Shiver DC ...

Page 2: ...309 R 1 23 5181138 2 24 5141203 2 25 505059LA A 1 26 502501LA 1 27 508983 B R 1 28 7051097LA 1 29 522349 2 30 5321006 2 31 528008 2 32 701192 C 2 32 701191 C 2 33 520263BZ 2 34 523254BZ 2 35 549062LA 2 36 501466LA 1 37 505055LA 1 38 505056LA 1 39 501467LA 1 40 526127KR C 1 41 900709 1 42 520317PN 8 43 900710 1 44 850716 1 45 547626 1 46 547633 1 47 531067 2 49 520264AC 1 Shiver DC 190 Oil levels P...

Page 3: ...E WHEEL KIT 1 22 819309 R LH OUTER TUBE UNIT SHIV DC 05 1 23 5181138 PRELOAD SLEEVE 2 24 5141203 SPRING K 3 2 2 25 505059LA A LOWER HANDLEBAR CLAMP 1 26 502501LA LOWER CROWN 1 27 508983 B R ALLOY STEER TUBE DIA 30 1 28 7051097LA CROWN ALLOY STEM SHIVER DC 05 1 29 522349 WASHER 2 30 5321006 EXTERNAL PRELOAD ADJUSTER 2 31 528008 O RING 2 32 701192 C BLACK PLUG 2 32 701191 C RED PLUG 2 33 520263BZ AL...

Page 4: ...46 547633 LH RH GUARD LABELS SHIV DC 05 1 47 531067 BUFFER 2 49 520264AC IN CAP AXLE 1 Marzocchi Suspension 2005 Shiver DC ...

Page 5: ...um alloy forged and CNC machined Stanchions anodised aluminium Dropouts aluminium alloy CNC machined fixed solidly to the stanchion tubes Sliding bushings made of friction free and wear free material Springs constant pitch Seals computer designed oil seals that guarantee maximum seal in any condition Oil specially formulated oil that prevents foam and keeps the viscosity unchanged while offering h...

Page 6: ... damage the bolts making them impossible to loosen or tighten 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 Only use original Marzocchi spare parts Before servicing th...

Page 7: ...put some shims 2 onto the crown in correspondence of the steer tube If the position of the crown with respect to the sliders has been changed restore the original distance D After tuning the steering set tighten screws 3 onto the top crown to the recommended tightening torque 10 Nm 1 Over tightening screws 3 can deform the tubes and weaken the structure Tighten the steer tube fixing screw 4 to the...

Page 8: ...h Use only brake systems that comply with the forks specifications The brake cable must never touch the crown and stanchions Warnings Assembling the wheel For a correct operation of the fork install the wheel as explained below Insert the wheel axle 1 through the right dropout the wheel and the left dropout With the 6mm Allen wrench tighten the left screw 2 to the recommended tightening torque 15 ...

Page 9: ...len wrench lock the handlebar mount tightening screws 2 to the recommended tightening torque 10 Nm 1 Fit the handlebar right in the middle of the mount Lock the handlebar in position with the special U bolt 3 With a 5mm Allen wrench tighten screws 4 to the recommended tightening torque 10 Nm 1 On request special adapters 5 are available to install handlebars with a different diameter Marzocchi Sus...

Page 10: ... the stop ring 8 With a 21mm socket spanner fully unscrew lock cap 1 Remove the lock cap 1 Remove pusher 7 from the threaded pin 6 of the pumping element taking into account that these two parts have a left hand threading Dismantling Draining the oil Remove the fork legs from the steering crowns Remove washer 1 the preload tube 2 and spring 3 from both legs Marzocchi Suspension 2005 Shiver DC ...

Page 11: ...tling Dismantling the hydraulic cartridge Proceed as follows for both legs Turn the fork leg upside down and loosen the bottom nuts 8 with a 15mm socket spanner Pull out bottom nuts 8 complete with O rings 9 Pull the complete cartridges 5 off the fork legs Holding locknut 1 with a 10mm fixed spanner loosen the threaded pin 2 using a 7 5mm fixed spanner Marzocchi Suspension 2005 Shiver DC ...

Page 12: ...V cartridges 5 are sealed through machining and cannot be overhauled In the case of faults or a malfunctioning they must be replaced Dismantling Breaking down stanchion tube slider and removing the sealing rings Pull stanchion 5 out of slider 6 Marzocchi Suspension 2005 Shiver DC ...

Page 13: ...ize off the metal stop ring 2 Take great care not to damage the internal surfaces of the slider while removing the stop ring Protect the upper part of the slider with the special tool A With a screwdriver prize off the sealing ring 3 Remove the sealing ring 3 Take great care not to damage the internal surfaces of the slider while removing the sealing ring Marzocchi Suspension 2005 Shiver DC ...

Page 14: ...bush 9 knock the end of the slider against a wooden surface Do this operation with extreme caution and hold the slider perpendicular to the wooden surface If this operation is difficult by hand use the bush extractor being very careful not to scratch the internal surfaces of the slider Marzocchi Suspension 2005 Shiver DC ...

Page 15: ... seal and the sealing ring with some grease Insert the sealing ring 3 in its seat with the special introducer A Using a hammer knock in introducer A and drive the sealing ring home into the slider Using a small flat tip screwdriver fit stop ring 2 and check that it fits perfectly into its groove Take great care not to damage the internal surfaces of the slider when fitting the stop ring Insert dus...

Page 16: ...elow Do not at any times reverse the position of the pumping elements in the fork legs if you are unsure about anything please refer to the relevant exploded view Assembling Assembling the cartridge Proceed as follows for both legs Insert the spring guide tube 7 in the cartridge rod Tighten locknut 1 on the cartridge rod Marzocchi Suspension 2005 Shiver DC ...

Page 17: ...d pin 2 to the recommended tightening torque 6 Nm 1 Insert the complete cartridge 5 Using a 15mm socket spanner tighten the bottom nuts 8 with O rings 9 to the recommended tightening torque 10 Nm 1 Assembling Filling with oil Block the fork in the vice in perfectly vertical position Fully lower sliders and cartridges Marzocchi Suspension 2005 Shiver DC ...

Page 18: ... in every phase Lift the sliders with cartridges off the stanchion tubes Insert spring 3 the preload tube 2 and washer 1 in both legs Assembling Mounting the top caps Put the fork in the vice in vertical position fixing it by the dropouts Tighten pusher 7 on the threaded pin 6 In this way the stop ring groove on the same pin will be visible once the cap has been assembled The pusher and the thread...

Page 19: ...nner tighten to the recommended tightening torque 10 Nm 1 Mount the stop ring 8 Mount the adjusting knob 5 and with a 1 5mm Allen wrench tighten the grubscrew 4 to the recommended tightening torque 1 5 Nm 2 Marzocchi Suspension 2005 Shiver DC ...

Page 20: ...ump can compromise the inflating operation and cause malfunction or damage to the fork resulting in an accident personal injury or death Once the correct setting has been found we recommend noting the number of clicks or turns of the adjuster with respect to the fully closed position adjuster fully clockwise for a faster re setting of your fork in case of need Setting SAG SAG means the fork bottom...

Page 21: ...instable and the mountain bike will have a tendency to snake A too slow setting however will cause problems when dealing with multiple obstacles where the suspension can t return to its fully extended position fast enough between one obstacle and the next Turning adjuster A clockwise increases the hydraulic damping making the fork slower during the rebound phase Turning adjuster A counter clockwis...

Page 22: ... fixing screws 10 1 Preload knob locking grubscrews 1 5 0 2 Preload knob locknut 6 1 Pumping element cartridge bottom nuts 10 1 Top crown fixing screws 10 1 Wheel axle Allen screws 10 1 Wheel axle screws 15 1 Position Oil type Quantity cc Right fork leg SAE 7 5 550013 170 Left fork leg SAE 7 5 550013 170 Marzocchi Suspension 2005 Shiver DC ...

Page 23: ...ad Oil is too fluid Check oil levels Fork stays down or packs up during multiple impacts Rebound damping is too high Decrease rebound damping with the relevant register Front wheel tends to tuck under while turning left or right Rebound damping is too high Decrease rebound damping with the relevant register Heavy amount of oil on stanchions oil dripping down legs Sealing rings damaged Renew all se...

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