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Maintenance

024

English

112

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.

WARNING

The operations listed below accompanied by this symbol

must be performed only by

MARZOCCHI authorized centres.

Table 4.1:

Problems - Diagnosis - Solutions

Problem

Diagnosis

Solution

Fork has too much sag

Spring rate too soft or fork

oil too fluid

Increase spring preload

Add spring preload by replacing

the preload tube

Check the oil level

Change to stiffer spring rate

Increase air pressure

Forks bottoms too easily, but it

has the recommended sag

Not enough compression

damping

Increase compression damping

by changing oil level

Increase compression damping

through the proper adjuster

Fork bottoms too easily;

needs more than maximum

preload

Spring rate too soft or fork

oil too fluid

Check oil level

Install stiffer springs

Increase air pressure

Fork does not get full travel

Spring rate too stiff or fork

oil level too high

Check oil level

Install 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) with a

higher viscosity

Fork bottoms out too quickly

Not enough compression

damping

Increase compression damping

at the travel end via the proper

adjuster

Front wheel wants to tuck

under while cornering

Too much rebound

damping; spring rate too

soft

Decrease the rebound damping

Increase spring rate

Содержание BOMBER 2005

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Страница 3: ... could be seriously injured or killed while engaged in 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 co...

Страница 4: ...atch and will void the forks warranty 1 Identify Your Riding Style 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 di...

Страница 5: ...e Table Below Please see your Marzocchi retailer or contact Marzocchi directly if you require assistance in selecting the correct fork Tab 1 2005 Fork Riding Categories and Intended USE Trekking XC Marathon All Mountain Urban Riding Dirt Jumping Freeriding Extreme Freeriding Downhill TXC EXR All Mountain SL Dirt Jam Comp Drop Off 66 RC TXC ECC EXR Pro All Mountain 1 Dirt Jam Pro Shiver SC 66 R EXR...

Страница 6: ...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 with an experienced rider before attempting any jump or drop WARNING Failure to properly flow around obstacles on the trail or failure to properly land after a jump or drop could cause...

Страница 7: ...MZ024 no 49 Use and maintenance instruction manual Engli sh ...

Страница 8: ... Shiver series forks 108 3 4 5 Wheel installation on Monster series forks 109 3 5 Fender Installing 110 3 6 Handlebar clamp installing 110 3 6 1 Handlebar clamp installing on all dual crown models except the 888 series 110 3 6 2 Handlebar clamp installing on 888 series 111 4 Maintenance 112 4 1 Problems Diagnosis Solutions 112 4 2 General maintenance recommendations 114 4 3 Cleaning the fork legs ...

Страница 9: ...aintenance table 113 Table 5 1 TST control positions table 119 Table 5 2 Forks adjustments 120 Table 6 1 Summarizing tables reading 121 Table 6 2 Mx Series 122 Table 6 3 Marathon Series 124 Table 6 4 All Mountain Series 126 Table 6 5 Dirt Jumper Series 130 Table 6 6 D Street 24 131 Table 6 7 Z1 FR Series 132 Table 6 8 66 Series 135 Table 6 9 888 Series 136 Table 6 10 Junior T 137 Table 6 11 Moster...

Страница 10: ...sociated with the fork that are not actually a part of the fork MARZOCCHI reserves the right in its sole discretion to make changes to the products at any time and without prior notice 1 1 Conventions 1 1 1 Orientation of the fork Picture 1 Conventional orientation of the fork TOP BOTTOM B A C K F R O N T LEFT RIGHT MZ024001 1 1 2 Editorial pictograms WARNING Descriptions preceded by this symbol c...

Страница 11: ...arathon RACE Air Marathon SL Air Marathon XC Air Coil spring All Mountain SL Air All Mountain 1 Air Coil spring All Mountain 2 Air Coil spring Air Coil spring All Mountain 3 Air Coil spring Air Coil spring Dirt Jumper I Coil spring Dirt Jumper II Coil spring Dirt Jumper III Coil spring D Street 24 Coil spring Z1 FR SL Air Z1 FR 1 Coil spring Z1 FR 2 Coil spring Z1 FR 3 Coil spring 66 RC Coil sprin...

Страница 12: ...T cartridge Marathon SL TST cartridge DOPPIO AIR Cartridge Marathon XC TST cartridge TAS Cartridge All Mountain SL TST cartridge DOPPIO AIR Cartridge All Mountain 1 TST cartridge TAS Cartridge All Mountain 2 SSV damping rod with rebound inside adjustment Not adjustable SSV damping rod HSCV cartridge with rebound outside adjustment ETA cartridge SSVF damping rod with rebound outside adjustment All ...

Страница 13: ...V pumping rods can have a fixed setting or adjustable rebound by internal adjusters SSVF in the SSVF system the evolution of the SSV system the fork s sensitivity is further improved thanks to the spring preloaded valve SSVF pumping rods can have a fixed setting or adjustable rebound by internal adjusters HSCV the HSCV system allows more controlled damping by adjusting the fork s sensitivity to th...

Страница 14: ...en Bath system reduces the maintenance frequency compared to a sealed cartridge system On the models using elastomers a correct inside lubrication is made by means of grease 2 4 Sliding bushing and oil seals 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 by means...

Страница 15: ...dels 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 the shaded area shown in Picture 2A 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 The distance betw...

Страница 16: ... brake system manufacturer Use only brake systems that comply with the fork s specifications taking into consideration the contents of the summarizing tables contained in this manual Table 3 1 Brake system settings Picture 3 Braking system settings Fork V brake setting Disk maximum dimensions Marathon except Marathon Race MX V brake removable setting XC INTL STD 6 Marathon Race V brake fixed setti...

Страница 17: ...g bigger dimensions you will have to verify that The tire turns freely there is no contact with the brake arch or the V Brake system The distance between the inflated tire and the lower part of the lower crown keeping the fork s legs fully compressed must be at least 4 mm 3 4 Wheel axle securing system Picture 4 The system for securing the wheel axle to the fork sliders can be standard with tradit...

Страница 18: ...low the instructions here below when installing the wheel Insert the axle 5A through the right fork wheel axle clamp the wheel and the left fork wheel axle clamp Tighten the axle acting on the cap 5B using a 6 mm Allen key to the required tightening torque 15 1 Nm Check the correct fork wheel alignment by fully compressing the fork a few times The wheel should not make contact with or come close t...

Страница 19: ...5 1 Nm Check the correct fork wheel alignment by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake Check the owners manual for the brake system for the proper specifications Tighten the screws 6B positioned on both whe...

Страница 20: ... 1 Nm Check the correct fork wheel alignment by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake Check the owners manual for the brake system for the proper specifications Tighten the screws 7C positioned on both whee...

Страница 21: ...on the left side to the required torque 15 1 Nm Check the correct fork wheel alignment by fully compressing the fork a few times The wheel should not make contact with or come close to any portion of the fork Lift the front of the bicycle and spin the wheel a few times to verify the correct alignment with the disk brake Check the owners manual for the brake system for the proper specifications Tig...

Страница 22: ...ar clamp installing on all dual crown models except the 888 series Picture 10 For the installation please carefully follow these instructions Install the handlebar lower mounting 10A on the upper crown in a way that the holes coincide Fix the handlebar clamp by tightening the screws 10B to the required torque 10 1Nm using a 5 mm Allen key Install the handlebar in the mounting in a central position...

Страница 23: ...e screws 11B to the required torque 6 1Nm using a 4 mm Allen key Install the handlebar in the mounting in a central position Lock the handlebar with the appropriate clamp 11C Tighten the screws 11D to the required torque 6 1 Nm using a 4 mm Allen key You can find reduction shells 11E as a spare part if needed to allow installation of handlebars having different diameter Picture 11 Handlebar clamp ...

Страница 24: ...easily but it has the recommended sag Not enough compression damping Increase compression damping by changing oil level Increase compression damping through the proper adjuster Fork bottoms too easily needs more than maximum preload Spring rate too soft or fork oil too fluid Check oil level Install stiffer springs Increase air pressure Fork does not get full travel Spring rate too stiff or fork oi...

Страница 25: ... 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 Unusual soundscoming from the TAS cartridge TAS cartridge is damaged Contact a service center to verify the correct fork s functi...

Страница 26: ... of screwdriver to unscrew slotted or crosshead Phillips 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 you have any questions regarding the care maintenance ...

Страница 27: ...his 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 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...

Страница 28: ... use of any other pump can compromise the inflating operation and cause malfunction or damages to the fork NOTE Once you have found the best setting we suggest taking note of the adjuster clicks or the number of turns as to the all closed position adjuster completely turned clockwise so that it will be easier to re establish the original setting after possible changes 5 1 Adjustment kit and spring...

Страница 29: ...r crown and the dust seal and take note of the value A Repeat the measurement sitting on the bike and take note of the value B Picture 13 How to measure SAG SAG A B How to find the best SAG The best sag corresponds to 15 20 for Cross country forks and to 25 30 for Freeride forks In order to calculate the best SAG for your own fork you will only need to do following calculation SAG T x S T total tr...

Страница 30: ...ound speed adjustment is made through internal or external adjusters 5 7 Compression adjustment You can control the compression speed through the compression adjuster The compression adjustment can be done according to the user s needs and it must prevent the fork s bottoming A hard compression adjustment offers more stability and allows a more aggressive riding style making the mountain bike more...

Страница 31: ...he maximum travel and the fork s length WARNING Never force the knob past its limit as the fork could be damaged and become dangerous for the rider 5 10 TST Terrain Selection Tecnology The TST system allows adjustment of the suspension damping The TST cartridge is provided in the lower area with a rebound adjuster see par 5 6 Rebound adjustment and in the upper area with a 5 positions compression ...

Страница 32: ...ction Tecnology MX Comp X2 X2 RH LH Tab 6 2 MX Pro X2 X2 RH LH Marathon RACE X2 RH RH LH LH Tab 6 3 Marathon SL X2 LH LH RH RH Marathon XC RH RH LH LH RH All Mountain SL X2 LH LH RH RH Tab 6 4 All Mountain 1 RH RH LH LH RH All Mountain 2 X2 X2 RH RH LH All Mountain 3 X2 X2 LH Dirt Jumper I X2 RH Tab 6 5 Dirt Jumper II X2 RH Dirt Jumper III X2 D Street 24 X2 Tab 6 6 Z1 FR SL X2 LH LH RH RH Tab 6 7 ...

Страница 33: ...2 75 3 40 40 50 4 20 60 Positive air pressure TST leg UNLOCK LOCK ETA Left leg When turning the knob clockwise you activate the ETA cartridge function When turning the knob counterclockwise you reset the fork s normal function All Mountain 1 All Mountain 2 All Mountain 3 All Mountain SL All Mountain 1 All Mountain 2 110 130 130 150 110 130 130 150 adjustable via negative air the 8 brake system ins...

Страница 34: ...ly for ETA versions Remove protection cap Fully tighten the pump adapter on the valve and inflate air to the required pressure Mount the protection cap Spring preload with air Both legs Remove protection cap Fully tighten the pump adapter on the valve and inflate air to the required pressure Mount the protection cap 85 105 120 MX Comp Air MX Comp Coil MX Comp ETA 85 105 120 85 105 120 STD STD STD ...

Страница 35: ...er during the rebound phase When turning the adjuster clockwise you will decrease the rebound hydraulic braking making the fork more responsive during the rebound phase After adjustment has been made put the cap back to its seat and tighten it to the required torque 10 1 Nm Inflate to the suggested pressure LOCK UNLOCK ETA Left leg When turning the knob clockwise you activate the ETA cartridge fun...

Страница 36: ...r to the required pressure Mount the rubber protection cap and reset the correct adjustment via the TST knob Positive air DOPPIO AIR cartridge Left leg Right leg on Marathon Race Unscrew and remove the protection cap Fully tighten the pump adapter on the valve positioned outside and inflate air to the required pressure Fully tighten the protection cap Negative air DOPPIO AIR cartridge Left leg Rig...

Страница 37: ...ent you will have to completely deflate the positive air chamber located on the right leg then re establish the correct working pressure Marathon Race Marathon SL Marathon XC Marathon Race Marathon SL Marathon XC Marathon XC Rebound adjustment with external register Right leg Left leg on Marathon Race When turning the adjuster clockwise you increase the rebound hydraulic braking making the fork sl...

Страница 38: ...eset the correct adjustment via the TST knob Positive air DOPPIO AIR cartridge Left leg Unscrew and remove the protection cap Fully tighten the pump adapter on the valve positioned outside and inflate air to the required pressure Fully tighten the protection cap Negative air DOPPIO AIR cartridge Left leg Unscrew and remove the protection cap Fully tighten the pump adapter on the valve positioned i...

Страница 39: ...he valve and inflate air to the required pressure Mount the protection cap All Mountain 2 All Mountain 3 All Mountain 2 All Mountain 2 All Mountain 2 All Mountain 3 Spring preload with air HSCV cartridge Remove the rubber protection cap marked with AIR and turn the rebound adjustment knob until you uncover the air valve Fully tighten the pump adapter on the valve and inflate air to the required pr...

Страница 40: ...m All Mountain 2 Rebound adjustment with internal register Right leg Using a small pointed object fully deflate the right leg pressure Fully unscrew and remove the cap using a 21 mm Allen key Insert the supplied hexagon rod into the stanchion tube making sure to center the adjustment seat When turning the adjuster counterclockwise you will increase the rebound hydraulic braking making the fork slo...

Страница 41: ...l increase the maximum travel and the fork s length Before proceeding to the TAS cartridge adjustment you will have to completely deflate the positive air chamber located on the right leg then re establish the correct working pressure Rider s weight Positive air pressure Negative air pressure PAR air pressure kg lbs lbs bar psi 55 70 120 155 2 00 2 75 30 40 70 80 155 180 2 40 3 10 35 45 bar psi 5 ...

Страница 42: ...aking making the fork slower during the rebound phase When turning the adjuster clockwise you will decrease the rebound hydraulic braking making the fork more responsive during the rebound phase After adjustment has been made put the cap back to its seat and tighten it to the required torque 10 1 Nm Inflate to the suggested pressure Rebound adjustment with external register Right leg When turning ...

Страница 43: ...0 both legs Spring preload with air both legs Remove the protection cap Fully tighten the pump adapter on the valve and inflate air to the required pressure Mount the protection cap 80 Removable setting the 8 brake system installation is allowed using an adapter provided by the brake system manufacturer ø 20 mm through hole axle INTL STD 6 V Brake T V D Street 24 32 mm 2 5 x 24 ...

Страница 44: ... and remove the protection cap Fully tighten the pump adapter on the valve positioned outside and inflate air to the required pressure Fully tighten the protection cap Negative air DOPPIO AIR cartridge Left leg Unscrew and remove the protection cap Fully tighten the pump adapter on the valve positioned inside and inflate air to the required pressure Fully tighten the protection cap Z1 FR SL Z1 FR ...

Страница 45: ... Mount the protection cap Z1 FR 1 Z1 FR 2 Z1 FR 2 Z1 FR 3 Z1 FR SL Z1 FR 1 Z1 FR 2 Rebound adjustment with external register Right leg When turning the adjuster clockwise you increase the rebound hydraulic braking making the fork slower during the rebound phase When turning the adjuster counterclockwise you decrease the rebound hydraulic braking making the fork more responsive during the rebound p...

Страница 46: ... the knob clockwise you activate the ETA cartridge function When turning the knob counterclockwise you reset the fork s normal function Z1 FR 1 Z1 FR 3 Rider s weight Positive air pressure Negative air pressure PAR air pressure kg lbs lbs bar psi 55 70 120 155 2 00 2 75 30 40 70 80 155 180 2 40 3 10 35 45 bar psi 5 00 15 00 73 217 bar psi 0 2 00 0 30 Preload air pressure bar psi 0 1 00 0 15 80 95 ...

Страница 47: ... braking at travel end When turning the adjuster counterclockwise you will decrease the compression hydraulic braking at travel end Spring preload with air HSCV cartridge Remove the rubber protection cap marked with AIR and turn the knob until you uncover the air valve Fully tighten the pump adapter on the valve and inflate air to the required pressure Mount the rubber protection cap and reset the...

Страница 48: ...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 notch to reduce it During the extraction and the insertion of the metallic wire be very careful not to damage the components If the pumping rod and m...

Страница 49: ...er during the rebound phase When turning the adjuster counterclockwise you decrease the rebound hydraulic braking making the fork more responsive during the rebound phase Compression adjustment Right leg 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 counterclockwise you wi...

Страница 50: ...ion is allowed using an adapter provided by the brake system manufacturer ø 20 mm through hole axle INTL STD 6 NO T V Shiver SC 30mm 2 8 x 26 Spring preload with external adjustment Both legs By turning the adjustment knob clockwise you increase the preload value By turning the adjustment knob counterclockwise you decrease the preload value Rebound adjustment with external register Both legs When ...

Страница 51: ...ng bolts Monster T Shiver DC 10 1 Fender fixing bolts 6 1 Handlebar clamp fixing bolts all dual crown except 888 Series 10 1 Handlebar clamp fixing bolts 888 Series 6 1 ETA knobs fixing bolts 2 0 5 TAS knobs fixing bolts 2 0 5 Rebound adjustment knobs fixing bolts 2 0 5 Compression adjustment knobs fixing bolts 2 0 5 Damping rod knobs fixing bolts with external lower adjustment 2 0 5 Pumping rods ...

Страница 52: ... or Marzocchi USA for the United States of America labor costs to remove the Marzocchi Suspension System from the bicycle or compensation for loss of use while the Marzocchi Suspension System is being repaired This warranty will be automatically void if serial number of the Marzocchi Suspension System is altered erased defaced or otherwise subject to any tampering PURCHASER This warranty is made b...

Страница 53: ...eplacement of defective materials as stated above No dealer and no other agent or employee of Marzocchi S p A or Marzocchi USA Inc is authorized to modify extend or enlarge this warranty WARNING Always install repair and use your Marzocchi Suspension System in strict compliance with it s owner s manual OTHER RIGHTS This warranty gives you the specific legal rights and you have also other rights wh...

Страница 54: ...MZ024 281 MARZOCCHI distributors and service centers EN You can find the updated distributors list on the Internet page www marzocchi com ...

Страница 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...

Страница 56: ...ike es SWEDEN MOTORFIRMAN HOLGER AB P O Box 6093 SE 400 60 Göteborg Sweden Phone 46 31 7276320 Fax 46 31 582234 info duells se www duells 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 Con...

Страница 57: ... 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 PHILIPPINES FAREN ENTERPRISES 59_E Bansalangin St Project 7 1105 Quezon City Philippines Tel 632 372 2541 Fax 632 372 2311 hansgee mydestiny net SINGAPORE CAPPA...

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Страница 59: ...Cod 9001060 Maggio 2004 Ed 00 ...

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