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General warnings for owners manual

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

structural integrity of the suspension system

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WARNING

 

 

 

 

 

 

and significantly reduce its lifespan.

Please

 

Failure to follow these instructions could

 

have your bicycle regularly inspected by a

 

result in failure of the product, an accident,

 

qualified mechanic for any oil leaks, cracks,

 

personal injury or death.

 

 

 

 

 

deformation, or other signs of fatigue.

The

 

 

 

 

 

 

 

 

 

 

 

 

frequency of inspection depends on many

 

 

 

 

 

 

 

 

 

 

 

 

factors; check with your authorized Marzocchi

 

1.

 

USE OF THE MANUAL

 

 

 

 

 

representative to select a schedule that is

 

Carefully read, follow and understand

the

 

best for you.

If the

inspection

reveals any

 

 

deformation,

cracks,

impact marks,

 

stress

 

 

instructions

given

in this

manual.

It is

an

 

 

 

 

 

marks or bent parts, no matter

how

 

slight,

 

 

essential part of the product, and you should

 

 

 

 

 

immediately

have

a

Certified

Marzocchi

 

 

keep it in a safe place for future reference.

 

 

 

 

 

 

Repair Center inspect the forks before you

 

• If

the

use

and

maintenance

instructions

 

 

 

ride again.

 

 

 

 

 

 

 

 

provided in this

manual

are

not

properly

• When installing or removing your bicycle from

 

 

performed, or if the other instructions in this

 

 

 

a bicycle carrier (roof

rack or

rear

hitch

 

 

manual are not followed, an accident could

 

 

 

 

mount), be sure that you fully loosen the quick

 

 

occur, resulting in an accident, serious injury

 

 

 

 

release fastener on the carrier. In addition, be

 

 

or death.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

sure that your bicycle is lifted from or installed

 

Please be advised that suspension system

 

 

 

on the carrier in a perfectly vertical direction.

 

 

installation and repair requires specialized

 

If the quick release fastener is not fully

 

 

knowledge,

tools and experience.

General

 

loosened, or if there is any bending action

 

 

mechanical aptitude may not be sufficient to

 

while installing or removing your bicycle, you

 

 

properly install or repair your suspension

 

will scratch, bend or otherwise damage your

 

 

system.

 

Please

have

your

suspension

 

suspension system.

 

 

 

 

 

 

 

system installed and/or serviced only by an

• If you strike at any speed any overhead

 

 

authorized Marzocchi Service Center.

 

 

 

 

 

 

 

object, such as a parking garage, bridge, tree

 

Never make any modification whatsoever to

 

 

 

limb or other abutment, with your bicycle while

 

 

any component of your suspension system.

 

your bicycle is attached to a bicycle carrier,

 

 

 

 

 

 

 

 

 

 

 

 

you can damage your forks. Have your forks

 

A.

 

GENERAL SAFETY RECOMMENDATIONS

 

inspected by an authorized Marzocchi Service

 

 

 

Center before you ride.

 

 

 

 

 

• Be sure to use the correct suspension system

 

 

 

 

 

 

Always wear a properly fitted and fastened

 

 

for your style of riding. Check the “Intended

 

 

 

bicycle helmet that

has been approved by

 

 

Use Instructions” in this manual.

 

 

 

 

 

 

 

 

 

 

ANSI or SNELL, and any other safety

 

• Please

note that

there

are inherent risks

 

 

 

equipment necessary for your riding style.

 

 

associated with downhill, free ride, cross

 

 

 

 

 

 

 

 

 

 

country, marathon, trekking, dirt jumping and

B.

BEFORE EVERY RIDE

 

 

 

 

 

urban style riding. You could be seriously

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

injured or killed while engaged in those riding

Check that none of the components to your

 

 

styles. Learn how to ride, never ride beyond

 

suspension system, or the remainder of your

 

 

your capabilities, be sure to use the proper

 

bicycle, are bent, deformed, cracked or

 

 

safety equipment, and be sure that all your

 

otherwise damaged.

 

 

 

 

 

 

 

riding equipment is in excellent condition.

 

Check to be sure that all quick release

 

The lifespan of Marzocchi products depends

 

 

fasteners, nuts and bolts are properly

 

 

on many factors, such as riding style and

 

adjusted. Bounce the bicycle on the ground

 

 

riding conditions. Impacts, falls, improper use

 

and listen and look for anything which may be

1

 

or harsh use in general may compromise the

 

loose.

 

 

 

 

 

 

_

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MZ009

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. 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. It 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

1

brakes.

MZ009_

 

Free Ride (FR): This riding style is for skilled

 

riders and involves aggressive slopes, large

 

obstacles, and moderate jumps. Free Ride

9

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 (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.

WARNING

Ride only in areas specifically designated for your riding style.

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

10

selecting the correct fork.

 

Tab 1: 2004 Fork Riding Categories and Intended USE

XC/Marathon

Free Riding

DJ/Urban Riding

Down Hill/Extreme

Trekking

 

 

 

Free Riding

 

 

Z-150 Free Ride

 

 

 

 

Z-150 FR SL

 

 

 

 

Z-150 Drop-Off

Dirt Jumper I

 

 

Marathon SL

Z.1 FR SL

Monster T

TXC

Dirt Jumper II

Marathon S

Z.1 FR

Super Monster

TXC ECC

Dirt Jumper III

 

Z.1 Drop-Off I

 

 

 

 

 

 

 

Z.1 Drop-Off II

 

 

 

 

Z.1 Wedge

 

 

 

MX Comp

Shiver SC

Shiver SC

Super T Pro

 

MX Pro

 

 

 

 

 

MZ Comp

Drop Off Comp

Street DJ

Junior T

 

MZ Race

 

 

 

 

 

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 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 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

REMEMBER

 

 

 

Even forks made out of solid metal will fail if they are misused, abused, or

improperly

used!

11

Extreme use can eventually wear out and break even the strongest components.

 

 

 

 

 

“Ride fast, yet ride Smart”

MZ009_1

Use and maintenance instruction manual

English

 

MZ009_1

English

I

96

Contents

CONTENTS

 

11

Introduction - General Safety

 

 

Regulations.......................................

98

1.1

Conventions.....................................

98

1.1.1 Orientation of the fork .................

98

1.1.2 Editorial pictograms....................

98

1.2Use application of the BOMBER

 

 

forks.................................................

99

 

 

 

 

22

 

Technical information ....................

100

2.1

Fork’s external components...........

100

2.1.1

Fender ......................................

100

2.1.2

Legs protections .......................

100

2.1.3 Wheel axle securing system.....

101

2.2Fork’s internal components and

 

fork’s operation ..............................

114

33

Installation ......................................

116

3.1

Installing on the frame ...................

116

3.2

Installing the brake system ............

117

3.3Wheel installing with a standard

fork’s end .......................................

118

3.4Wheel installing with a QR20

Plus fork.........................................

118

3.5Wheel installing with a QR20

“With Bolt” fork...............................

119

3.6Wheel installing with a 888

Series fork .....................................

120

3.7Wheel installing with a Monster

Series fork .....................................

121

3.8Wheel installing with a Shiver fork. 122

55

Adjustments....................................

128

5.1

Preload...........................................

129

5.1.1Spring preload with external

adjustment ................................

129

5.1.2Spring preload with internal

 

adjustment ................................

130

5.1.3

Internal spring preload ..............

131

5.1.4

Air preload ................................

132

5.2 Negative air....................................

133

5.3Cartridge forks rebound

adjustment .....................................

134

5.4Rebound adjustment with external

adjustable pumping rod..................

135

5.5Rebound adjustment with internal

adjustable pumping rod..................

135

5.6 Compression adjustment ...............

136

5.7Compression adjustment at

 

 

bottoming .......................................

136

5.8

ECC5 .............................................

137

5.9

ETA ................................................

137

 

 

 

 

66

 

Tables ..............................................

138

 

 

 

 

77

 

Warranty ..........................................

139

 

 

 

 

10.

Notes

141

N

 

 

Marzocchi distributors and service

 

 

centers.............................................

281

3.9

Fender installing ............................

122

44

Maintenance ...................................

123

4.1Problems - Diagnosis - Solutions .. 123

4.2

General safety regulations.............

125

4.3

Cleaning the fork legs....................

126

4.4

Air Bleeding ...................................

127

MZ009_1

TABLE INDEX

 

Table 1:

Use application of the

 

 

MY 2004 BOMBER FORKS ........

99

Table 2:

Marathon - Mx Series ................

102

Table 3:

Marathon 29er - Mx Series 29er 103

Table 4:

Dirt Jumper Series.....................

104

Table 5:

Street DJ....................................

105

Table 6:

Z1 Wedge ..................................

106

Table 7:

Z-1 Series ..................................

107

Table 8:

Z-150 Series ..............................

108

Table 9:

Shiver 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

Table 21: Recommended positive air

 

 

pressure for air forks..................

138

Table 22: Recommended negative air

 

 

pressure.....................................

138

Table index

English

I

97

MZ009_1

English

1

98

Introduction - General Safety Regulations

11

INTRODUCTION - GENERAL

the end of this manual or on the Internet page

 

SAFETY REGULATIONS

www.marzocchi.com.

Before reading this manual please carefully read

This manual does not explain how to assemble/

disassemble the fork from the bicycle, the

the information contained in the “Safety

wheel, the steering set or any other component

regulations for the manual’s user” section.

directly or indirectly associated with the fork that

The information contained in the “Safety

are not actually a part of the fork.

regulations for the manual’s user” section will

MARZOCCHI reserves the right to make

have to be followed for both, the MARZOCCHI

changes to the products, at any time and without

BOMBER forks’ and maintenance.

prior notice to improve the products or to meet

If you have any questions regarding the care

any productive or commercial requirements.

and maintenance of your suspension system,

The user is the only person responsible for the

please contact your nearest service center

correct application of the assembly instructions

directly. A list of service centers can be found at

in the present manual.

1.1 Conventions

1.1.1 Orientation of the fork

 

TOP

RIGHT

BACK

FRONT

LEFT

 

 

BOTTOM

MZ009001

1.1.2 Editorial pictograms

ATTENTION

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 environment.

NOTE

Descriptions preceded by this symbol contain information, prescriptions or procedures recommended by MARZOCCHI for the best fork’s use.

MZ009_1

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