Marzzochi Shiver DC Manual

MO

DEL YEA

R 2004

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General warnings for owners manual

WARNINGFailure to follow these instructions couldresult in failure of the product, an accident,personal injury or death.

1. USE OF THE MANUAL• Carefully read, follow and understand the

instructions given in this manual. It is anessential part of the product, and you shouldkeep it in a safe place for future reference.

• If the use and maintenance instructionsprovided in this manual are not properlyperformed, or if the other instructions in thismanual are not followed, an accident couldoccur, resulting in an accident, serious injuryor death.

• Please be advised that suspension systeminstallation and repair requires specializedknowledge, tools and experience. Generalmechanical aptitude may not be sufficient toproperly install or repair your suspensionsystem. Please have your suspensionsystem installed and/or serviced only by anauthorized Marzocchi Service Center.

• Never make any modification whatsoever toany component of your suspension system.

A. GENERAL SAFETY RECOMMENDATIONS• Be sure to use the correct suspension system

for your style of riding. Check the “IntendedUse Instructions” in this manual.

• Please note that there are inherent risksassociated with downhill, free ride, crosscountry, marathon, trekking, dirt jumping andurban style riding. You could be seriouslyinjured or killed while engaged in those ridingstyles. Learn how to ride, never ride beyondyour capabilities, be sure to use the propersafety equipment, and be sure that all yourriding equipment is in excellent condition.

• The lifespan of Marzocchi products dependson many factors, such as riding style andriding conditions. Impacts, falls, improper useor harsh use in general may compromise the

structural integrity of the suspension systemand significantly reduce its lifespan. Pleasehave your bicycle regularly inspected by aqualified mechanic for any oil leaks, cracks,deformation, or other signs of fatigue. Thefrequency of inspection depends on manyfactors; check with your authorized Marzocchirepresentative to select a schedule that isbest for you. If the inspection reveals anydeformation, cracks, impact marks, stressmarks or bent parts, no matter how slight,immediately have a Certified MarzocchiRepair Center inspect the forks before youride again.

• When installing or removing your bicycle froma bicycle carrier (roof rack or rear hitchmount), be sure that you fully loosen the quickrelease fastener on the carrier. In addition, besure that your bicycle is lifted from or installedon the carrier in a perfectly vertical direction.If the quick release fastener is not fullyloosened, or if there is any bending actionwhile installing or removing your bicycle, youwill scratch, bend or otherwise damage yoursuspension system.

• If you strike at any speed any overheadobject, such as a parking garage, bridge, treelimb or other abutment, with your bicycle whileyour bicycle is attached to a bicycle carrier,you can damage your forks. Have your forksinspected by an authorized Marzocchi ServiceCenter before you ride.

• Always wear a properly fitted and fastenedbicycle helmet that has been approved byANSI or SNELL, and any other safetyequipment necessary for your riding style.

B. BEFORE EVERY RIDE• Check that none of the components to your

suspension system, or the remainder of yourbicycle, are bent, deformed, cracked orotherwise damaged.

• Check to be sure that all quick releasefasteners, nuts and bolts are properlyadjusted. Bounce the bicycle on the groundand listen and look for anything which may beloose.

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• Be sure that your wheels are perfectlycentered. Spin the wheels to be sure thatthey do not wobble up and down or from sideto side, and that they do not make contactwith the fork legs or brake pads while rotating.

• Learn and follow the local bicycle laws andregulations, and obey all traffic signals, signsand laws while you ride.

DO NOT RIDE YOUR BICYCLE IF IT DOESNOT PASS THIS PRE-RIDE TEST. CORRECTANY CONDITION BEFORE YOU RIDE.

INTENDED USE INSTRUCTIONS

SELECT THE CORRECT FORK FORYOUR RIDING STYLE AND RIDEPROPERLY

Marzocchi suspension forks are among themost durable and technologically advancedforks on the market today. However, no fork canwithstand misuse, abuse or improper use that,over a short period of time, can cause your forksto fail when you least expect it.

It is critical that you select and use the fork thatis appropriate for your riding style, and that youuse the fork properly.

1. Identify Your Riding Style:

Trekking: Trekking is similar to XC riding butnot as aggressive as XC. It involves slowerriding and no riding over obstacles such asrocks, roots, or depressions. You should onlyattach generators and racks to the designatedmounting points provided on the forks. Nevermake any modification to your fork to attach anyequipment.

Cross Country (XC)/Marathon: Riding alonghilly trails where some bumps and smallerobstacles, such as rocks, roots, or depressions,may be encountered. XC riding does notinclude jumps or “drops” (riding off rocks, fallentrees or ledges) from any height. XC forks mustonly be used with tires specifically designed forcross country riding, or disk, rim or linear pullbrakes.

Free Ride (FR): This riding style is for skilledriders and involves aggressive slopes, largeobstacles, and moderate jumps. Free Rideforks should be used only with disk brakes aswell as frames, wheels and other componentsspecifically designed for Free Riding. The diskbrakes must be attached to the designatedmounting points provided on the fork. Nevermake any modification to your fork to attach anyequipment.

Dirt Jumper (DJ) / Urban Riding: This “BMX”or “motocross” style riding is only for the mostskilled riders and involves jumping from onemound of dirt to another. It also includes ridingover and around “urban obstacles” such asman-made or other concrete structures. Theseforks should be used only with disk brakes, aswell as frames, wheels and other componentsspecifically designed for this riding style. Thedisk brakes must be attached to the designatedmounting points provided on the fork. Nevermake any modification to your fork to attach anyequipment.

Down Hill (DH) / Extreme Free Ride: Thisdiscipline is only for professional or highly skilledriders. It includes for relatively high jumps or“drops” and negotiating larger obstacles such asboulders, fallen trees or holes. These forksshould be used only with disk brakes, as well asframes, wheels and other componentsspecifically designed for this riding style. Thedisk brakes must be attached to the designatedmounting points provided on the fork. Nevermake any modification to your fork to attach anyequipment.

WARNINGRide only in areas specifically designated foryour riding style.

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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 inselecting the correct fork.

Tab 1: 2004 Fork Riding Categories and Intended USE

XC/Marathon Free Riding DJ/Urban Riding Down Hill/Extreme Free Riding Trekking

Marathon SLMarathon S

Z-150 Free RideZ-150 FR SLZ-150 Drop-OffZ.1 FR SLZ.1 FRZ.1 Drop-Off IZ.1 Drop-Off IIZ.1 Wedge

Dirt Jumper IDirt Jumper IIDirt Jumper III

Monster TSuper Monster

TXCTXC ECC

MX CompMX Pro Shiver SC Shiver SC Super T Pro

MZ CompMZ Race Drop Off Comp Street DJ Junior T

EXR CompEXR ProEXR Supra

Drop-Off Triple888 R888 RR 888 RTShiver DC

3. Do Not Misuse or Abuse Your ForksDo not misuse or abuse your forks. Learn howto ride, and always ride within your abilities. Anout-of-control ride puts the equivalent of years ofhard use on your forks after only a few rides.Learn how to properly flow around obstacles onthe trail. Hitting obstacles such as rocks, treesor holes straight on puts forces on your fork itwas not designed to absorb. Landing improperly after a jump or drop alsoputs forces on your fork it was not designed toabsorb. You should only perform jumps ordrops when a transition or down ramp isavailable to help your bicycle absorb the impactforces generated during the landing, and bothwheels should smoothly make contact with thetransition or down ramp at the same time. Anyother type of landing is dangerous, as it couldresult in a component part failure and anaccident. The steepness and length of thetransition or down ramp depends on the heightfrom which you jump or drop. Every situation isdifferent for every rider; consult with anexperienced rider before attempting any jump ordrop.

WARNINGFailure to properly flow around obstacles onthe trail, or failure to properly land after ajump or drop could cause your forks to fail,resulting in a loss of bicycle control andserious injury or death to the rider.

Your forks require regular maintenance andrepair. The harder you ride, the more often youmust inspect and maintain your forks. If yourforks are bent, deformed, cracked, orchipped, no matter how slight, immediatelyhave a Certified Marzocchi Repair Centerinspect the forks before you ride again.

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REMEMBEREven 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”

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Use and maintenance instruction manual

English

Contents

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CONTENTS

1 Introduction - General SafetyRegulations....................................... 98

1.1 Conventions..................................... 981.1.1 Orientation of the fork ................. 981.1.2 Editorial pictograms.................... 98

1.2 Use application of the BOMBER forks................................................. 99

2 Technical information .................... 100

2.1 Fork’s external components........... 1002.1.1 Fender ...................................... 1002.1.2 Legs protections ....................... 1002.1.3 Wheel axle securing system..... 101

2.2 Fork’s internal components and fork’s operation .............................. 114

3 Installation ...................................... 116

3.1 Installing on the frame ................... 116

3.2 Installing the brake system ............ 117

3.3 Wheel installing with a standard fork’s end ....................................... 118

3.4 Wheel installing with a QR20 Plus fork......................................... 118

3.5 Wheel installing with a QR20 “With Bolt” fork............................... 119

3.6 Wheel installing with 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........................................... 1295.1.1 Spring preload with external

adjustment ................................ 1295.1.2 Spring preload with internal

adjustment ................................ 1305.1.3 Internal spring preload .............. 1315.1.4 Air preload ................................ 132

5.2 Negative air.................................... 133

5.3 Cartridge forks rebound adjustment ..................................... 134

5.4 Rebound adjustment with externaladjustable pumping rod.................. 135

5.5 Rebound adjustment with internaladjustable pumping rod.................. 135

5.6 Compression adjustment ............... 136

5.7 Compression adjustment at bottoming ....................................... 136

5.8 ECC5 ............................................. 137

5.9 ETA ................................................ 137

6 Tables .............................................. 138

7 Warranty .......................................... 139

10. Notes................................................ 141

Marzocchi distributors and servicecenters............................................. 281

1

2

3

4

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5

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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

I

Introduction - General Safety Regulations

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1 INTRODUCTION - GENERAL SAFETY REGULATIONS

Before reading this manual please carefully readthe information contained in the “Safetyregulations for the manual’s user” section.The information contained in the “Safetyregulations for the manual’s user” section willhave to be followed for both, the MARZOCCHIBOMBER forks’ and maintenance.If you have any questions regarding the careand maintenance of your suspension system,please contact your nearest service centerdirectly. A list of service centers can be found at

the end of this manual or on the Internet pagewww.marzocchi.com. This manual does not explain how to assemble/disassemble the fork from the bicycle, thewheel, the steering set or any other componentdirectly or indirectly associated with the fork thatare not actually a part of the fork.MARZOCCHI reserves the right to makechanges to the products, at any time and withoutprior notice to improve the products or to meetany productive or commercial requirements.The user is the only person responsible for thecorrect application of the assembly instructionsin the present manual.

1.1 Conventions1.1.1 Orientation of the fork

TOP

BOTTOM

BACK

FRONT LEFT

RIGHT

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1.1.2 Editorial pictograms

ATTENTIONDescriptions preceded by this symbolcontain information, instructions orprocedures, which, if not respected, cancause damage or bad function to the fork,accidents to the user (even fatal ones) ordamage to the environment.

NOTEDescriptions preceded by this symbol containinformation, prescriptions or proceduresrecommended by MARZOCCHI for the bestfork’s use.

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1.2 Use application of the BOMBER forks

You will find in the following table the useapplications of MY2004 Marzocchi Bomberforks.

ATTENTIONDo not use forks for an application that isdifferent from the one provided by themanufacturer. For further informationconcerning the specific fork’s use, pleaserefer 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-Off I

Z-150 DO

Z-150 FR

Z-150 FR SL

Z1 FR

Z1 FR SL

MARATHONCROSS COUNTRY

FREERIDE DIRT JUMPERURBAN

DOWN HILLFREE RIDE EXTREME

Technical information

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2 TECHNICAL INFORMATION

2.1 Fork’s external componentsThe MY 2004 MARZOCCHI BOMBER forksrange includes many different models, havingfrom 30 to 40 mm legs diameter and travels upto 300 mm. Apart from a few exceptions, the MY2004 MARZOCCHI BOMBER forks rangeconsists of two main assemblies:

• the stanchion tubes / steering crownassembly (which are assembled through acryogenic process called “cryofit” for a stiffand undetachable fit).

• the magnesium-casted sliders/arch monolithassembly.

The materials used for the main components arethe BAM® aluminium from the aerospaceindustry and the magnesium; these arelightweight materials that help reduce the fork’sweight.

2.1.1 FenderMARZOCCHI offers an optional integratedfender for all models with ø32mm legs and forthe new forks of the 888 series.The fender mounted to the underside of thecrown helps protecting the rider against debrisfrom the front tire.

2.1.2 Legs protectionsThey are made of plastic material and arecurrent equipment on the upside-down models(Shiver SC and Shiver DC); they allow legsprotection from mud and dust that can be raisedby the front wheel during use; they also assurethe legs integrity from hits.

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2.1.3 Wheel axle securing systemThe system for securing the wheel axle to thefork sliders can be standard, with traditionaladvanced dropouts or with the QR20 Plussystem.

Forks using this system must have a suitablehub with 110 mm width spacing and a 20 mmwheel axle.

The MARZOCCHI QR20 Plus system: it is thenew, sophisticated version of the QR20 systemthat fully wraps the 20 mm wheel axle, formaximum stiffness, while still providing an easyway to remove the wheel.

The new QR20 Plus 20 mm axle system is

available in two different versions, both using aforged aluminium hinge that is attached to thelower magnesium slider. The forged aluminiumlever can be the quick-release one, whichmakes opening and closing the flap routine, or itcan be “with bolt”, where the clamping is madevia a screw tightening.

The 20 mm wheel axle used in both QR20 Plussystems can be the quick-release type or thebolt-on type.The upside down forks (Shiver SC and ShiverDC), as well as the models created for moreintensive use (888 Series and Monster Series)are provided with a wheel fastening systemoriginating from the motorcycle application,using a 20 mm axle.

Marzocchi Bomber wheel axle securing systems: (A) traditional advanced dropout, (B) QR20Plus, (C) QR20 With Bolt, (D) Shiver dedicated axle, (E) Monster dedicated axle, (F) 888 dedicatedaxle.

A B C

D E F


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Table 2: Marathon - Mx Series

ATTENTIONMarzocchi reserves the right to modify data and features quoted in the table here above, ifneeded for technical and/or commercial requirements. The dimensions indicated in thedrawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.

177

ø 30

80

100130

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

Mar

ath

on

& M

x S

erie

s

= current = option = not available

478

373

105

458

373

85

438

373

65#

493

373

120


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Table 3: Marathon 29er - Mx Series 29er


175

ø 30

80

100130

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


QR 20 Plus

QR 20 With Bolt

Accessories


Mar

ath

on

29e

r &

Mx

29er


495

410

85

505

410

100


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Table 4: Dirt Jumper Series


*: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


QR 20 Plus

QR 20 With Bolt

Accessories


Integrated fender

Dir

t Ju

mp

er S

erie

sD

Irt

Jum

per

I -

DIr

t Ju

mp

er II

- D

Irt

Jum

per

III


518

388

130

498

388

110

538

388

150#


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Table 5: Street DJ


177

80

110130

25

ø 32

A

C

320

ø 30

223

315

Max 65

mm

mm

mmS

tree

t D

J

468

388

80

Integrated fender

A (max)

A (min)

TRAVEL (C)

Disk brake mounts


QR 20 Plus

QR 20 With Bolt

Accessories


Ø 20 mm dedicated axle


V-brake fit


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Table 6: Z1 Wedge


175

ø 30

80

100130

18

ø 30

248

A

C

Max

340

353

Max 60

mm

mm

mmZ

1 W

edg

e

503

373

130

A (max)

A (min)

TRAVEL (C)

Disk brake mounts

V-brake fit


QR 20 Plus

QR 20 With Bolt

Accessories




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Table 7: Z-1 Series


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


QR 20 Plus

QR 20 With Bolt

Accessories



518

388

130Z

1 S

erie

s(e

xcep

t fo

r Z

1 W

edg

e)

V-brake fit

Integrated fender


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Table 8: Z-150 Series


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


QR 20 Plus

QR 20 With Bolt

Accessories


Integrated fender

Z15

0 S

erie

s


538

388

150


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Table 9: Shiver SC


ø 30

Max 68

Max

345

187

112135

C

ø 30

A

15

A (max)

A (min)

TRAVEL (C)

mm

mm

mm

Disk brake mounts

V-brake fit


QR 20 Plus

QR 20 With Bolt

Accessories



Sh

iver

SC


482

382

100


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Table 10: Junior T & Super T PRO


*: 110 with QR20 Drop outs

ø 32

C

100 *130

ø 30

Max

345

352

181

Max 68

18

AM

ax18

4

A (max)

A (min)

TRAVEL (C)

mm

mm

mm

Disk brake mounts

V-brake fit


QR 20 Plus

QR 20 With Bolt

Accessories


Jun

ior T

& S

up

er T

PR

O


558

388

170

Integrated fenderDirect mount handlebar clamp

(long or short)

Junior T Super T PRO


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Table 11: Shiver DC


110

208

ø 30

C

AM

ax14

5*

25

Max 68

Max

345

* : 163 with high crown

ø 35

A (max)

A (min)

TRAVEL (C)

mm

mm

mm

Disk brake mounts


QR 20 Plus

QR 20 With Bolt

Accessories



Direct mount handlebar clamp (long or short)

Sh

iver

DC


572

382

190

V-brake fit


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Table 12: 888 Series


A (max)

A (min)

TRAVEL (C)

mm

mm

mm

Disk brake mounts

V-brake fit


QR 20 Plus

QR 20 With Bolt

Accessories



Direct mount handlebar clamp Integrated fender

888

Ser

ies


575

405

170

605

405

200

17,5

C

A

202

ø 30

110145

ø 35

Max 73

Max

357

Max

160


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Table 13: Monster Series


ø 30

22534

ø 40

110175

Max 73

Max

357

A

C

Max

190

A (max)

A (min)

TRAVEL (C)

mm

mm

mm

Disk brake mounts

V-brake fit


QR 20 Plus

QR 20 With Bolt

Accessories

DH International Standard for 8” diskRear calliper mount

Mo

nst

er S

erie

s


593

393

200 (Monster)

693

393

300 (Super Monster)


Direct mount handlebar clamp (long or short)


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2.2 Fork’s internal components and fork’s operation

Inside MARZOCCHI forks you will find coilsprings or air as a spring system.

The damping load that is generated during thefork legs compression and rebound, can beadjusted by cartridges, controlled by externaladjusters, or by special hydraulic valve pumpingrods, which operate according to compressionspeed (Speed Sensitive Valving).Pumping rods can be controlled by external orinternal adjusters, or they can have a fixedsetting.

Cartridges and pumping rods are fully plungedin oil (Open Bath System). This system providesproper lubrication and cooling of the inner slidingparts; furthermore, the oil volume works as adamping and setting element.The Open Bath system reduces themaintenance frequency compared to a sealedcartridge system.

Stanchion tubes are guided in the sliders by twoteflon-coated bushings, free from static friction.

The seal system prevents oil leaks andcontamination from particles entering the fork. Ituses a special dual-lip oil seal and a dust seal atthe top of each slider.

You will find here below the different forkdamping systems:

ECC5: the new Extension Control Cartridgeoffers on-the-fly adjustment of the rebounddamping with a 5-position clicker. Use the fastrebound position for downhilling, the 3 middlepositions for race start sprints and roughclimbing and the fully closed ECC position forsteep dirt switchback climbs or Marathon styleroad climbs.

ETA: the new Extension Travel Adjustment locksdown the rebound damping like the standardECC, but still allows 25 - 30 mm of travel.

HSCV: the High-Speed Compression Valve(HSCV) allows lighter damping for better trailsensitivity but still resists bottoming. It is the best

way to provide a controlled dampingenvironment for consistent and perfect damping.The moving valve on the shaft controls reboundand low-speed compression damping. Thespecial valve in the bottom of the cartridge(HSCV), takes the edge of any hard hit tomaintain control.

SSV: the Speed Sensitive Valve (SSV) uses 5valve circuits to control damping rates based onthe fork’s compression and rebound speed aswell as the fork’s position in the travel.

SSVF: The latest version of our Speed SensitiveValve has a new Floating valve and springdesign. It incorporates a spring-loaded valve,which is more responsive and uses an externalrebound adjuster.


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Table 14: BOMBER forks damping systems

F/A= compression brakingF/R= rebound (or extension) braking

ForkDamping system

Right leg Left legDirt Jumper I SSV pumping rod with external adjustment SSV non-adjustable pumping rod

Dirt Jumper II SSV pumping rod with internal adjustment SSV non-adjustable pumping rod

Dirt Jumper III SSV non-adjustable pumping rod SSV non-adjustable pumping rod

Junior T SSV non-adjustable pumping rod SSV non-adjustable pumping rod

Marathon S HSCV F/R hydraulic cartridge ETA cartridge

Marathon SL ECC5 hydraulic cartridge Negative air cartridge

Monster T F/R adjustment cartridge in the upper area and F/A in the lower area

Final F/A external adjustment cartridge

MX Comp AIR SSV pumping rod with internal adjustment Non-adjustable pumping rod

MX Comp COIL SSV pumping rod with internal adjustment SSV pumping rod with internal adjustment

MX Comp + ETA SSV pumping rod with internal adjustment ETA Cartridge

MX Pro AIR SSVF pumping rod with external adjustment Non-adjustable pumping rod

MX Pro 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 hydraulic cartridge

Shiver SC HSCV F/R hydraulic cartridge HSCV F/R hydraulic cartridge

Street DJ SSV non-adjustable pumping rod SSV non-adjustable pumping rod

Super Monster F/R adjustment cartridge in the upper area and F/A in the lower area

Final F/A external adjustment cartridge

Super T PRO HSCV F/R hydraulic cartridge HSCV F/R hydraulic cartridge

Z1 Drop-Off I SSVF pumping rod with external adjustment ETA cartridge

Z1 Drop-Off II SSV pumping rod with external adjustment Non-adjustable pumping rod

Z1 Wedge SSV non-adjustable pumping rod SSV non-adjustable pumping rod

Z1 FR HSCV F/R hydraulic cartridge ETA cartridge

Z1 FR SL ECC5 hydraulic cartridge Negative air cartridge

Z-150 DO SSVF pumping rod with external adjustment ETA cartridge

Z-150 FR HSCV F/R hydraulic cartridge ETA cartridge

Z-150 FR SL ECC5 hydraulic cartridge Negative air cartridge

Installation

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3 INSTALLATION

3.1 Installing on the frameThe fork is supplied with “A-Head Set”(threadless) steer tube to be cut according toframe size it will be used on.Installing the fork on the bicycle frame is a verydelicate operation that must be carried out byspecialized personnel.

ATTENTIONThe assembling on the frame and the steertube adjustment must be carried out incompliance with the manufacturer’sinstructions. Improper installation mayjeopardize the safety of the rider.Marzocchi does not guarantee theinstallation and refuses all responsibility fordamages and/or accidents that may becaused by an incorrect installation.

The steer tube must be pressed into the crown;its replacement must be carried out by one ofour service centers only, using the requiredtools.

ATTENTIONIn case of improper installation of the steertube into the crown, the rider might losecontrol of his/her bicycle, thus jeopardizinghis/her safety.

ATTENTIONOn all dual crown MY 2004 BOMBER models,the lower crown is clamped to thestanchions (or to the sliders in the upside-down models) through some bolts. In thiscase, you will have to respect followingprecautions during installing:

• In case of oversized diameter areas on thestanchions or on the sliders, the crownsclamping can only be done in these areas(as shown in the picture).

• In case of reference notches on thestanchions or on the sliders, the lower partof the lower crown must be positionedover the notch.

• With the fork fully compressed, thedistance between the inflated tyre and the

bottom face of the steering crown shall begreater than 4 mm.

• On the Monster forks the distance betweenthe lower part of the lower crown and thedust seal must be bigger than 4 mm.

• In the dual crown models, the maximumlength of the steering tube between thetwo crowns shall be less than the valuesindicated in the following table

888 160 mmJunior T e Super T PRO 184 mmShiver DC (with standard steering crown) 145 mm

Shiver DC (with high steering crown) 163 mmMonster Series 190 mm

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3.2 Installing the brake systemInstalling the brake system is a very delicateoperation that must be carried out byspecialized personnel.

ATTENTIONMarzocchi does not guarantee theinstallation and accepts no liability fordamage and/or accidents arising from awrong installation.Improper installation of the disk brakesystem can overstress the calipermountings, which may break. Theinstallation of the brake system must becarried out following the instructions of thebrake system manufacturer. Improperinstallation can be dangerous for the rider.Use only brake systems in accordance withthe 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 brakemounts or V-brake mounts.

• The transformation from one brakingsystem to the other must be done byqualified 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 lockthe upper part of the slider to the arch. Inthe case of installation of a disk brakesystem, the service centres can replacebolts (A) with screws (B).

• The user is not allowed to remove bolts (A)or screws (B).

• Do not replace screws (B) with commercialbolts.

• On the thread of bolts (A, C) and screws(B) a special anti-unscrewing treatmenthas been applied; as a result, the removedbolts cannot be re-used as they lose suchtreatment.

• When a disk braking system is mounted,before any use, check that the brake tubeis correctly fixed to the special mount (D,E).

A

B

A

B C

D

E

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3.3 Wheel installing with a standard fork’s end

ATTENTIONInstall the wheel in compliance with themanufacturer’s instructions.

For correct fork function after wheel installingyou will need to:

• check the correct fork-wheel alignment byfully compressing the fork a few times.

• lift the front wheel above the ground; turn thewheel a few times to verify the correctalignment with the disk brake or the V-brakepads.

3.4 Wheel installing with a QR20 Plus fork

For correct fork function, please follow theinstructions here below when installing thewheel:• Release the securing system on both legs by

pushing the levers (A) downwards and openthe flap (P)

• For quick-release hubs, open the releaselever (B).

• For threaded cap hubs, unscrew the cap (C)as much as needed to insert the wheel axlethrough the fork wheel axle clamp.

• Insert the wheel axle (D) through the forkwheel axle clamp.

• Make sure that the wheel axle supportingbushings (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 the cappositioned on the axle side using a 6 mmAllen key to the required tightening torque(see Table - Tightening Torques).

• Verify the correct settling of the supportingbushings (E)

• Check the correct fork-wheel alignment, byfully compressing the fork a few times.

• Lift the front wheel; turn the wheel a few timesto verify the correct alignment with the diskbrake.

• Lock the securing system by pulling the levers(A) upwards and adjust clearance through theadjusters (H), if needed.

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E

B

D

A

C

P

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B

A

E

H

C

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3.5 Wheel installing with a QR20 “With Bolt” fork

For correct fork function, please follow theinstructions here below when installing thewheel:

• Using a 6 mm Allen key unscrew both screws(L) as much as needed to open the securingdevice (M)

• For quick-release hubs, open the releaselever (B).

• For threaded cap hubs, unscrew the cap (C)as much as needed to insert the wheel axlethrough the fork wheel axle clamp.

• Insert the wheel axle (D) through the forkwheel axle clamp.

• Make sure that the wheel axle supportingbushings (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 cappositioned on the axle side using a 6 mmAllen key to the required tightening torque(see Table - Tightening Torques).

• Verify the correct settling of the supportingbushings (E)

• Check the correct fork-wheel alignment, byfully compressing the fork a few times.

• Lift the front wheel; turn the wheel a few timesto verify the correct alignment with the diskbrake.

• Lock the wheel axle securing device (M) andtighten both screws (L) using a 6 mm Allenkey.

6 mm

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B

C

L

M

D

6 mm

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E

M

C

L

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3.6 Wheel installing with a 888 Series fork

For correct fork function, please follow theinstructions here below when installing thewheel:

• Insert the wheel axle (A) through the rightwheel axle clamp, the wheel and the leftwheel axle clamp.

• Lock and keep locking the wheel axle from theright side using a 6 mm Allen key, then stillusing a 6 mm Allen key tighten the wheel axleup to the required torque (see Table -Tightening Torques), acting on the cap (C)

• Fully compress the fork a few times toproperly align the fork legs.

• Using a 5 mm Allen key tighten to the requiredtorque (see Table - Tightening Torques) thebolts (B) positioned on both dropouts, with thesequence 1-2-1.

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A

6 mm

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C

5 mm

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B

B

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3.7 Wheel installing with a Monster Series fork

For a correct fork’s function, please follow theinstructions here below when installing thewheel.

• In case the fork has been disassembled fromthe bike frame or the fork’s legs position as tothe crowns has been changed, you will haveto slightly loose the 6 bolts (E) holding thearch (D) by means of a 4 mm Allen key.


• By using a 6 mm Allen key tighten the axlebolt (B) located on the left side to the requiredtorque (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 therequired torque (see Table - TighteningTorques), with the 1-2-1 sequence.

• By using the 4 mm Allen key tighten the bolts(E) with the sequence 1-2-3-2-1 to therequired torque (see Table - TighteningTorques).

ATTENTIONAn incorrect wheel alignment can lead toloss of proper legs sliding.

5 mm

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4 mm

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9

E E

D

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5

A

6 mm

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0200

6

B

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3.8 Wheel installing with a Shiver forkFor correct fork function, please follow theinstructions here below when installing thewheel:


• Screw down the bolt (B) on the left side andtighten to the required torque (see Table -Tightening Torques).

• Fully compress the fork a few times toproperly align the fork legs.

• Tighten to the required torque (see Table -Tightening Torques) the bolts (C) positionedon both dropouts, with the sequence 1-2-1.

3.9 Fender installingThe Ø 32 mm legs forks and the 888 Seriesforks can be equipped with an integrated fender.The fender can be provided with the fork orpurchased separately.When assembling the fender (F) you must insertthe small support bushing (H) between thescrew and the fender as shown in the picture,and tighten the screws (G) with a 8 mm Allenwrench to the required torque (see Table -Tightening Torques).

8 mm

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F

H

G

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1

A

6 mm

MZ0

0102

2 B

5 mm

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C

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4 MAINTENANCE

4.1 Problems - Diagnosis - SolutionsThis paragraph indicates some of the problems that may arise during the fork’s use, as well as thepossible causes of these problems and the suggested solutions.Always check this table before working on the fork.

Table 15: Problems - Diagnosis - SolutionsProblem Diagnosis Solution

Fork has too much sag

Spring rate too soft or fork oil too fluid

Add spring preload by replacing the preload tube

Check the oil height

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 levelIncrease compression damping through the proper adjuster

Fork bottoms too easily; needs more 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 pressureFork extends too quickly; harsh top-out after impacts

Not enough rebound dampingIncrease rebound dampingReplace oil (SAE 7,5) with a higher viscosity

Fork gets easily to travel end

Not enough compression damping

Increase compression damping at 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

Fork “packs up” or stays down in travel during multiple impacts

Too much rebound damping Decrease rebound damping

Knocking sound during rebound, but no harsh top-out

Too much rebound damping Decrease rebound damping

4

Operations to be carried out at MARZOCCHI authorized centres

Maintenance

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Table 16: Periodical maintenance table


Problem Diagnosis SolutionOil “ring” on stanchions Oil seals are contaminated Replace all seals

Heavy amount of oil on stanchions; oil dripping down legs

Seals are damaged, stanchions could be damaged

Replace all seals and have the stanchions 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 sensitivityWorn sliding bushings Replace sliding bushings

Old oil Change oil

General maintenance operationUse

Intense NormalCheck screws tightening up to required torque Before every ride

Clean the sliders After every rideAir pressure control Before every ride 10 hours

Check the oil seals 25 hours 50 hours

Oil change 50 hours 100 hours

Oil seals replacement 50 hours 100 hours

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4.2 General safety regulations

• After a complete breakdown, always use new,original Marzocchi seals when reassembling.

• To tighten two bolts or nuts that are near eachother, always follow the sequence 1-2-1 usingthe required tightening torque (see Table -Tightening Torques).

• Never use flammable or corrosive solvents toclean the parts, as these could damage theseals. If necessary use specific detergentsthat are not corrosive, not flammable or havea high flash point, compatible with the sealsmaterials and preferably biodegradable.

• If you are planning not to use your fork for along time, always lubricate the forkscomponents that are in contact with somefork’s oil.

• Never pour lubricants, solvents or detergentswhich are not completely biodegradable inthe environment; these must be collected andkept in the relevant special containers, thendisposed of according to the regulations inforce.

• Use only metric spanners, not imperialspanners, which may have similar sizes, butcan damage the bolts and make it impossibleto unscrew them.

• Use the correct size and sort of screwdriver tounscrew slotted or crosshead screws.

• When using a screwdriver to assemble ordisassemble metal stop rings, o-rings, slidingbushings or seal segments, avoid scratchingor cutting the components with thescrewdriver tip.

• Do not carry out any maintenance and / oradjustment operations that are not explainedin this manual; if necessary, have suchoperations carried out by an authorizedservice centre.

• Only proceed to maintenance/overhauloperations if you are sure you are able to do itand you have got the right tools. If this is notthe case, or if you are unsure, please contactan authorized service center, wherespecialized technicians with the right toolsand original spare parts will service andoverhaul your fork, putting it back into itsoriginal working conditions.

• Only use original spare parts.

• Work in a clean, ordered and well-lit place; ifpossible, avoid servicing outdoors.

• Polished surfaces need to be periodicallytreated with some “polishing compound” to bekept as bright as new.

• Carefully check there are no metal shavingsor dust in the work area.

• Do not modify the fork’s components.

Maintenance

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4.3 Cleaning the fork legs

NOTEThe manufacturer lubricates the fork dust sealwith some grease, which makes the stanchiontubes slide easier, especially when the fork hasnot been used for a long time. When using thesuspension system, such grease can melt andstick to the stanchions, looking like an oil leak,although it is not.

Clean using specific, biodegradable, notcorrosive and not flammable detergents.

• After every use, carefully clean the fork payingspecial attention to the stanchion tubes andthe dust seals.

ATTENTIONMud and dust, if not eliminated immediately,may cause serious damage to thesuspension system.

In the Bomber forks, except for the ø30mmmodel, it is also possible to clean the seat of thedust seal as described below.

ATTENTIONDo not clean the seat of the dust seal on theø30mm model.

• With a small screwdriver prize the dust seal(B) off the slider (C), without scratching thestanchion tube.

• Slide the dust seal along the stanchion tubeand clean inside the dust seal and its seat onthe slider with a jet of compressed air.

NOTEIt is advisable to tilt the fork leg to make it easierto remove foreign matters.

ATTENTIONNever use metal tools to clean any particlesof dirt.

• Compress the fork legs slightly and removeany traces of dirt from the stanchion tubes.

• Lubricate the dust seal and the visiblesurfaces of the oil seal with silicone grease.

• Re-assemble the dust seal (B) in its seat onthe stanchion tube, pressing it home with yourhands.

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A

B

C

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3

B

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4.4 Air Bleeding

NOTEThis operation must be carried out with the forkassembled on the bicycle and with the fork’slegs fully extended (front wheel off the ground).

NOTEThe pressure generated by the air that can getinto the fork legs while the bike is being usedand which, due to the special shape of the oilseals remains trapped inside, can cause thefork to malfunction.

In case of malfunction or loss of legs’smoothness please carry out followingoperation on both legs:

• By means of a 2 mm Allen key, unscrew theair bleed screw (A) located on the cap, inorder to drain the pressure generated insidethe fork’s leg.

• Check the oil seal (B) condition; replace ifneeded.

• Tighten the air bleed screw (A) to therecommended torque (see Table - TighteningTorques), being careful not to damage the oilseal (B).

2 mm

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A

B

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5 ADJUSTMENTS

ATTENTIONPlease visit our web site www.marzocchi.com for any information concerning the travelincrease kit and for different spring rates (K).

Table 17: MY04 adjustments table

The Mx Pro Coil model can be supplied with a PLe register 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

5.1.25.1.1See paragraph 5.1.3 5.1.4 5.2 5.3 5.6 5.7 5.4 5.5 5.8 5.9

888 RR

Fork A+ A- REBC PRiPRe ECC5 ETAPLiPLe PLmi ECA EHSC

Non-adjustable model

5

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Table 18: LegendPLe External Preload Spring preload with external adjuster

PLmi Internal mechanic Preload Spring preload with internal mechanical adjusterPLi Internal Preload Internal PreloadA+ Positive Air Preload Positive Air PreloadA- Negative Air Preload Negative Air Preload

REBC Rebound cartridge Rebound CartridgeECA External Compression Adjust External Compression Adjust

EHSC External High Speed Compression External High Speed CompressionPRe External rebound register External rebound registerPRi Internal rebound register Internal rebound register

ECC5 5 position extension control cartridge 5 position extension control cartridge

ETA Extension travel adjustment cartridge Extension travel adjustment cartridge

5.1 PreloadTo make the most of the fork’s travel, the saggiven by the rider’s weight must remain between10% and 20% of the total travel length for theXC forks and between 20% and 30% for the DHforks.To reach this result, act on the spring preloadadjusters or change the pressure in the forklegs.

5.1.1 Spring preload with external adjustment

NOTEThe fork is set to the minimum preload by themanufacturer, i.e. the adjuster knob/screw iscompletely turned counterclockwise. However,the spring is slightly preloaded to helpcounteractining static load.

By turning the knob (A) on the top of the fork’sleg, you can modify the spring preload to adjustthe initial setting according to the rider’s weightand needs.

• By turning the knob clockwise, the preloadspring can be increased up to the maximumvalue, which corresponds to a springcompression of about 15 mm

• By turning the knob counterclockwise, you willreduce the preload spring down to theminimum value.

ATTENTIONDo not force the adjustment knob past itslimits (A).

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A

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5130

MZ0

1001

2

A

4 mm

MZ0

0903

4

B

5.1.2 Spring preload with internal adjustment

NOTEThe fork is set to the minimum preload by themanufacturer, i.e. the adjuster is completelyturned counterclockwise. However, the spring isslightly preloaded to help counteractining staticload.

To adjust the initial setting according to therider’s weight and needs, you will have toremove the plastic protection cap (A) and turnthe adjuster (B), using a 4 mm Allen key.

• By turning the adjsuter clockwise, the preloadspring can be increased up to the maximumvalue.

• By turning the adjuster counterclockwise, youwill reduce the preload spring down to theminimum value.

Once the adjustment completed put the plasticprotection cap (A) back to its seat.

ATTENTIONDo not force the adjuster past its limits (B).

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9

A

MZ0

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0

C

D

B

5.1.3 Internal spring preloadThe 888R and 888RR models have arevolutionary coil preload system.The spring preload adjustment must be carriedout in respect of the procedure here belowexplained:

• Using a 26 mm wrench unscrew both fork’supper caps (A).

• Lower the stanchions as much as needed toallow the shaft to come out the cartridge.

• Press and keep pressing downwards thewasher (B) supporting the spring.

• Using a small screwdriver, take off from itsseat the metallic wire (C) that is locking thewasher (B) supporting the spring.

• Keep the washer pressed and insert themetallic wire into a lower notch to increasepreload, or into an upper notch to reduce it.

ATTENTIONDuring the extraction and the insertion of themetallic wire be very careful not to damagethe components.If the pumping rod and more precisely themetallic wire are even slightly damaged, donot use the fork in any case and immediatelycontact a Marzocchi authorized servicecentre.Do not alter the metallic wire.

• Lift the stanchions and tighten the fork’supper cap (B) using a 26 mm wrench up tothe required torque (see Table - TighteningTorques).

ATTENTIONDuring the insertion of the cartridge insidethe stanchion be very careful not to damagethe O-Ring (D).

Adjustments

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A

D

MZ0

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2

C

B

L

H

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0902

3

E

5.1.4 Air preload

ATTENTIONTo inflate your fork, use only the specialMARZOCCHI pump with pressure gauge,which you can buy at the authorized centers.Use of improper tools might lead to improperinflating and cause improper function ordamage to the fork itself.

NOTEIf you need to reduce the pressure inside thefork’s leg, just push lightly on the valve pin, bymeans of a pointed object. Apply the samepreload pressure on both legs.

By pressurizing air through the valve (D), youcan adjust the damping of the forces generatedduring the COMPRESSION phase.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 moresophisticated adjustment system and a differentair valve: in this case, to adjust the air preload,you will need the supplied dedicated adapter.

Right leg positive air adjustment:• Using a 2mm Allen wrench, loosen the screw

(C) fixing the ECC5 knob.

• Pay attention that pin (L) and spring (H) donot come out of their seat.

• Remove screw (C) and knob (B).

• Fit and tighten the adapter of the inflationpump (E) to the valve.

• Inflate till reaching the pressure you wish.

• Refit the knob (B).

• Using the 2mm Allen wrench, tighten thescrew (C) to the recommended torque (seetable - Tightening Torques).

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4

A

MZ0

0902

5

B

MZ0

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6

C

Left leg positive air adjustment:• Unscrew and remove the dust cap (A)

• Fully tighten the pump adapter on the outsidevalve (B)

• Inflate air up to the required pressure

• Fully tighten the dust cap (A)

ATTENTIONRespect the suggested pressures:• Spring forks: see Table - Recommended

pressures for spring forks• Air forks: see Table - Recommended

pressures for air forks

5.2 Negative air

ATTENTIONTo inflate your fork, use only the specialMARZOCCHI pump with pressure gauge,which you can buy at the authorized centers.Use of improper tools might lead toimproper inflating and cause improperfunction or damage to the fork itself.

By pressurizing air through the valve, you canadjust the damping of the forces generatedduring the REBOUND phase.

If you increase the pressure inside the fork’s leg,you increase the rebound damping.To do so, you need to:

• unscrew and remove the dust cap (A).

• fully tighten the pump adapter on the valve(C), that is located in the central position.

• inflate air up to the required pressure.

• fully tighten the dust cap (A)

Adjustments

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5.3 Cartridge forks rebound adjustmentThe extension (or rebound) damping adjustmentcan be made, according to the models, byrotating the adjustment knob (A) directly, or,where the knob is not available, by acting on theadjustment screw (B), using a proper flat tipscrewdriver. In both cases you will modify the hydraulicconfiguration of the inner valves, regulating therebound.

NOTEOn the models provided with compressionhydraulic damping adjustment at travel end, therebound damping adjuster located on the top ofthe right leg can be easily recognized thanks tothe “R” carved on the knob or on the cap.

• When turning the adjuster clockwise, you willincrease the rebound hydraulic damping,making the fork return slower during therebound phase.

• When turning the adjuster counterclockwise,you will decrease the rebound hydraulicdamping, making the fork more responsiveduring the rebound phase.

ATTENTIONDo not force the adjustment screws (A, B)past their limits.

MZ0

0902

8

A

MZ0

0902

1

B

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5135

MZ0

0903

6

B

21 mm

MZ0

0901

6

A

MZ0

0901

7

B

C

5.4 Rebound adjustment with external adjustable pumping rod

When turning the adjustment knob (B) locatedon the bottom of the fork’s leg, you can adjustthe damping during the rebound phase.By turning on the adjustment screw you canmodify the hydraulic configuration of the innervalves: this means that there will be more orless oil flowing through the valve.

• When turning the adjuster clockwise, you willincrease the rebound hydraulic damping,making the fork slower during the reboundphase.

• When turning the adjuster counterclockwise,you will decrease the rebound hydraulicdamping, making the fork more responsiveduring the rebound phase.

ATTENTIONDo not force the adjustment knob (B) past itslimits.

5.5 Rebound adjustment with internal adjustable pumping rod

You will find some damping rods where therebound adjustment is located inside thestanchion tube.To adjust these forks, you will need to:

• remove the dust cap (A) located on the top ofthe fork’s leg.

• insert the supplied hexagon rod (B) into thestanchion tube, making sure to center theadjustment seat (C)

• When turning the adjuster counterclockwise,you will increase the rebound hydraulicdamping, making the fork slower during therebound phase.

• When turning the adjuster clockwise, you willdecrease the rebound hydraulic damping,making the fork more responsive during therebound phase.

ATTENTIONDo not force the adjustment screw (C) pastits limits.

Adjustments

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5136

MZ0

0903

7 T

MZ0

0902

7

A

MZ0

0903

5

B

5.6 Compression adjustmentBy acting on the adjustment screw (T), locatedon bottom of the right leg, you can control thefork’s compression damping.By turning the adjustment screw and using aproper small flat tip screwdriver, you can adjustthe hydraulic configuration of the inner valvesthat control the compression.

• When turning the adjuster clockwise, you willincrease the compression hydraulic braking,reducing the travel made by the fork, underthe same stress.

• When turning the adjuster counter clockwise,you will decrease the compression hydraulicbraking, making the fork softer against groundharshness.

ATTENTIONDo not force the adjuster screw (T) past itslimits.

5.7 Compression adjustment at bottoming

The compression damping adjustment can bemade, according to the models, by rotating theadjustment knob (A) directly, or, where the knobis not available, by acting on the adjustmentscrew (B), using a proper flat tip screwdriver. In both cases you will modify the hydraulicconfiguration of the inner valves, regulating therebound.

NOTEThe compression damping adjuster atbottoming can be easily recognized thanks tothe “C” carved on the knob or on the cap.

• When turning the adjuster clockwise, you willincrease the hydraulic braking, preventing thefork to bottom out.

• When turning the adjuster counter clockwise,you will decrease the hydraulic braking.

ATTENTIONDo not force the adjustment screws (A, B)past their limits.

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5.8 ECC5The ECC5 cartridge offers on-the-fly adjustmentof the rebound damping.By turning on the adjuster (A) you can modifythe hydraulic configuration of the inner valves,controlling the flow of more or less oil, up to the“LOCK OUT” position, where no oil flowsthrough.Adjustment is possible through a 5-positionclicker.Position 1: “LOCK OUT”When the knob is fully tightened clockwise, youwill get the maximum rebound damping. In thisposition the fork’s legs will stay down afterimpacts; any other impact will make lower thefork’s geometry further.This position is only suitable for hard, steepclimbs.Position “2-3-4”By turning the knob counterclockwise topositions 2-3-4, you will get less reboundresistance accordingly.Position 5: “MINIMUM EXTENSIONDAMPING”When the knob is fully turned counterclockwise,you will reach the position of minimumextension damping, giving the fork themaximum response.

ATTENTIONDo not use the LOCK OUT n.1 position, forany reason, while riding hard downhill, asthe fork could not react safely enough whenhitting obstacles.

5.9 ETAThe ETA cartridge offers on-the-fly adjustmentof the rebound damping by reducing the fork’slength while still maintaining 30 mm of travel.By turning the small lever (B) clockwise you willactivate the ETA cartridge function.By turning the small lever (B) counterclockwise,you will bring your fork to its normal function andthe travel-reducing device will be no longer beengaged.

ATTENTIONDo not use the ETA device, for any reason,while riding hard downhill, as the fork couldnot react safely enough when hittingobstacles.

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6 TABLESTable 19: Tightening torques

Table 20: Recommended positive air pressure for spring forks

Table 21: Recommended positive air pressure for air forks

Table 22: Recommended negative air pressure

Components to be tightened Tightening Torque (Nm)Wheel axle bolts 15 ± 1Wheel axle allen bolts 10 ± 1Fork’s upper caps (all except 888 Series) 20 ± 1Fork’s upper caps (888 Series) 15 ± 1Upper crown fixing bolts 6 ± 1Lower crown fixing bolts 6 ± 1Fender fixing bolts 6 ± 1Handlebar clamp fixing bolts (all dual crown forks except 888 Series) 10 ± 1Handlebar clamp fixing bolts (888 Series) 6 ± 1ECC5 and ETA knobs fixing bolts 2 ± 0,5Pumping rods and cartridges fixing foot nuts 11 ± 1Cartridges fixing foot nuts 25 ± 1Cantilever bolts fixing screws 11 ± 1Pumping rods knobs fixing screws with lower, external adjustment 2 ± 0,5Preload knobs fixing pins 1,5 ± 0,5Air bleed screw 3 ± 0,5Arch bolts (Monster series) 6 ± 1

Positive air pressure0 ÷ 15 psi 0 ÷ 1 bar

Rider’s weight Positive air pressure120 ÷ 155 lbs 55 ÷ 70 kg 30 ÷ 40 psi 2.0 ÷ 2.75 bar155 ÷ 180 lbs 70 ÷ 80 kg 35 ÷ 45 psi 2.40 ÷ 3.10 bar180 ÷ 210 lbs 80 ÷ 95 kg 42 ÷ 52 psi 2.90 ÷ 3.80 bar

210 ÷ 220+ lbs 95 ÷ 100+ kg 52 ÷ 65 psi 3.60 ÷ 4.5 bar

Negative air pressure0 ÷ 150 psi 0 ÷ 10,3 bar

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parties. The rights of the original purchaserunder this warranty may not be assigned.

3. TERM. The term of this warranty shallcommence on the date of purchase andshall continue for a period of two (2) yearsfrom the date of the original purchase.

4. PROCEDURE. In event of a defect coveredby this warranty, the purchaser shouldcontact an authorized Marzocchi dealer or aMarzocchi Service Centre (for the USA,Marzocchi USA).

5. ENTIRE AGREEMENT. This warrantysupersedes any and all oral or expresswarranties, statements or undertakings thatmay previously have been made, andcontains the entire agreement between theparties with respect to the warranty of thisMarzocchi Suspension System. Any and allwarranties not contained in this warranty arespecifically excluded.

6. DAMAGES. Except as expressly providedby this warranty, Marzocchi S.p.A. SHALLNOT BE RESPONSIBLE FOR ANYINCIDENTAL OR CONSEQUENTIALDAMAGES ASSOCIATED WITH THE USEOF THE MARZOCCHI SUSPENSIONSYSTEM OR A CLAIM UNDER THISAGREEMENT, WHETHER THE CLAIM ISBASED ON CONTRACT, TORT OROTHERWISE. The foregoing statements ofwarranty are exclusive and lieu of all otherremedies. Some states do not allow theexclusion or limitation of incidental orconsequential damages, so this limitation orexclusion may not apply to you.

7. DISCLAIMER. ANY IMPLIED WARRANTYOF MERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSE AND ALLIMPLIED WARRANTIES ARISING FROMA COURSE OF DEALING, USAGE OFTRADE, BY STATUTE OR OTHERWISE,IS HEREBY STRICTLY LIMITED TO THETERM OF THIS WRITTEN WARRANTY.This Agreement shall be the sole andexclusive remedy available to the Purchaserwith respect to this purchase. In the event ofany alleged breach of any warranty or anylegal action brought by the purchaser based

7 WARRANTYIf any component of your Marzocchi SuspensionSystem is found to be defective in materials orworkmanship within the term of this Limited TwoYear Warranty (the “Agreement”), the defectivecomponent will be repaired or replaced, at theoption of Marzocchi S.p.A., free of charge,within thirty (30) days after receipt of theSuspension System by an authorized Marzocchidealer (for the USA, Marzocchi USA), freightprepaid, together with the original retail invoiceor other evidence of the date of purchase.

1. NOT COVERED: This warranty does notcover damage resulting from accidents,alteration, neglect, misuse, abuse, orimproper use, lack of reasonable or propermaintenance, improper assembly, repairsimproperly performed or replacement partsor accessories not conforming to MarzocchiS.p.A.’s specifications, modifications notrecommended or approved in writing byMarzocchi S.p.A., activities such asacrobatics, stunt jumping, ramp riding,racing, commercial use, and / or normalwear or deterioration occasioned by the useof the suspension system. Items subject tonormal wear or deterioration include but arenot limited to oil, dust seals, oil seals, andbushings. In addition, this warranty is voidin the event that the forks are used with anyrental bicycles, unless Marzocchi S.p.Aprovided prior approval in writing for suchuse. This warranty also does not includeany expenses related to the transportationof the Marzocchi Suspension System to orfrom an authorized Marzocchi dealer (forthe USA, Marzocchi USA), labor costs toremove the Marzocchi Suspension Systemfrom the bicycle, or compensation forinconvenience or loss of use while theMarzocchi Suspension System is beingrepaired. This warranty will beautomatically void if serial number of theMarzocchi Suspension System is altered,erased, defaced or otherwise subject to anytampering.

2. PURCHASER. This warranty is made byMarzocchi S.p.A. with only the originalpurchaser of the Marzocchi SuspensionSystem and does not extend to any third

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on alleged negligence or other tortiousconduct by Marzocchi S.p.A. thePurchaser’s sole and exclusive remedy willbe repair or replacement of defectivematerials as stated above. No dealer and noother agent or employee of MarzocchiS.p.A. is authorized to modify, extend orenlarge this warranty.

8. WARNING. Always install, repair and useyour Marzocchi Suspension System in strictcompliance with it’s owner’s manual.

9. OTHER RIGHTS. This warranty gives youthe specific legal rights, and you have alsoother rights which vary from state to state(USA only).

10. APPLICABLE LAW. Any disputes arisingout of this agreement or the use of thisMarzocchi Suspension System will begoverned by the laws of the country of Italyand will be decided by the Courts ofBologna, Italy.

NOTEThank you for the purchase of this MarzocchiSuspension System. If any defect coveredunder the warranty appears with the agreedterms, send the Marzocchi Suspension System,postage prepaid, to an authorized dealer or to aMarzocchi Service Center (for the USA,Marzocchi USA) including a copy of the invoiceor the ticket. When doing so, please state your full name,address, date of purchase and explain theproblem of defect. The policy of Marzocchi S.p.A. is to offercorteous and efficient service with respect towarranty claims.Please take care of your Marzocchi SuspensionSystem and in case you suspect it can bedamaged, please contact your dealer or aMarzocchi Service Center (for the USA,Marzocchi USA).

MARZOCCHI and BOMBER trademarkslicensed by Marzocchi S.p.A.

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MARZOCCHI distributorsand

service centers

Marzocchi distributors and service centers

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MARZOCCHI DISTRIBUTORS AND SERVICE CENTERSEUROPE

COUNTRY COMPANY

AUSTRIA

TRENDSPORT GmbHSüdtirolerstr., 1 - A6911 LOCHAU – AustriaContact: Mr. Klaus Froeis Tel.: +43 (0)5574 47147 • Fax: +43 (0)5574 [email protected]

BELGIUM

RAKBIKE S.A.Avenue Jeanne 13 – 1050 IXELLES - BelgiumContact: Rafi KasparianTel. +32 (0)2 6466682 • Fax +32 (0)2 [email protected] • www.rakbike.nethings.net

DENMARK

SCAN BIKEFrichsvej 17 – DK-8600 SILKEBORG - DenmarkContact: Lars MunskøTel.: +45 (0)86 80 54 88 • Fax: +45 (0)86 80 54 [email protected]

FINLAND

OY DUELL BIKE-CENTER ABJuhanilantie 4a - 01740 VANTAA – FinlandContact: Jussi LaurikainenTel.: +358 (0)6 322 7500 • Fax: +358 (0)6 322 [email protected] • www.duellbike.fi

FRANCE

PHILAMY S.A.1384, Parc Industriel Saint-Maurice - F 04100 Manosque – FranceContact: Derrick CoetzerTel. +33 (0) 4 92 70 97 00 • Fax: +33 (0) 4 92 72 60 [email protected] • www.philamy.com

GERMANY

COSMIC SPORTS GmbH Ipsheimerstr. 15-17 - D-90431 NÜRNBERG – GermanyTel. +49 911 31 07 55 0 • Fax: +49 911 3107 55 [email protected] • www.cosmicsports.de

ITALY

LARM SPAVia Cà dell’Orbo, 36 – 40055 Villanova di Castenaso (BOLOGNA) - ItalyTel. +39 0516053460 • Fax +39 [email protected]

OFFICIAL DISTRIBUTOR ALSO FOR:ALBANIA – TURKEY – GREECE – BOSNIA HERZEGOVINA – CROATIA – YUGOSLAVIA – SLOVENIA – MACEDONIAN – BULGARIA – HUNGARY – ROMANIA – POLAND - CZECH REPUBLIC – SLOVAKIA – MOLDAVIA – UKRAINE – BELARUS – LITHUANIA – LITTON – ESTONIA – RUSSIA – ASIA – OCEANIA – JAPAN - SOUTH AFRICA

NORWAY

SPORTPARTNER ASPOSTBOKS 555, BERGEN 5884 – NorwayTel. +47 55 50 6464 • Fax +47 55 50 [email protected] • www.sportpartner.no

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PORTUGAL

TAVARES & TIMMERMANS, Lda. Bike CenterCondomínio Industrial de Alcolombal – Estrada de Alcolombal, Armazém 12705-833 TERRUGEM-SINTRA – PortugalContact: Hans TimmermansTel. +351 (0)21 961 06 21 • Fax +351 (0)21 961 06 [email protected] • www.bikecenter-pt.com

SPAIN

TEAM BIKE S.L.Elche Parque Industrial c/ Juan de la Cierva, 8703203 Torrellano-Elche Alicante SpainContact : SimonTel.: +34 965 68 35 34 • Fax: +34 965 68 05 [email protected]

SWEDEN

AVENIX ABImportgatan 17 – 422 46 HISINGS BACKA - Sweden Tel. +46 (0)31 52 20 00 • Fax +46 (0)31 52 20 10 [email protected] • www.derbysweden.se

SWITZERLANDLIECHTENSTEIN

INTERCYCLEHaldenmattstr. 3 – CH-6210 SURSEE – SwitzerlandTel.: +41 (0)41 9266511 • Fax: +41 (0)41 [email protected] • www.intercycle.com

THE NETHERLANDSLUXEMBURG

AUGUSTA BENELUX BVRoosveltstraat 46 – NL 2321 BM LEIDEN – The NetherlandsContact: Mr. Koeman • Tel. +31 (0) 71 5791580 • Fax +31 (0) 71 [email protected]

UNITED KINGDOMIRELAND

SOLENT UK Ltd. t/a WindwaveUnit 9 Clarence Wharf Industrial Estate – Mumby Road - GOSPORTHants PO12 1AJ - UKTel. +44 (0)23 92521912 • Fax +44 (0)23 [email protected] • www.windwave.co.uk

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OTHER COUNTRIES

COUNTRY COMPANY

AUSTRALIA

GROUPE SPORTIF PTY. LTD.20 Harker Street, BURWOOD, Victoria 3125 – AustraliaTel.: +61 3 9888 9882 • Fax: +61 3 9888 [email protected] • www.groupesportif.com

BRAZIL

PLINIO CURI IMP. EXP.LTDSRwa Pamplona 8185 Andar - 01405-030 SAO PAOLO – BrasilTel.: +55 11 2510633 • Fax: +55 11 [email protected]

CANADA

NORCO PRODUCTS LTD.1465 Kebet WayPORT COQUITLAM, B.C. V3C 6L3 CanadaTel.: +1 604 552 2930 • Fax: +1 604 552 [email protected] • www.norco.com

PHILIPPINES

FAREN ENTERPRISES#59_E Bansalangin St., Project 7 - 1105 Quezon City – PhilippinesTel. +632 372 2541 • Fax +632 372 [email protected]

ISRAEL

CYCLE TRADING COMPANY LTD.Hapardes Rd.RISHPON, IsraelTel.: +972 9 9513010 • Fax: +972 9 [email protected] • www.ctc.co.il

KOREA

FOURS69-6 Jeongja-Dong Bundang-GuSeongnam-Si, KYONGGI-DO, KoreaTel.: +82 (0)31 719 6520/21 • Fax: +82 (0)31 719 [email protected]

SINGAPORE

CAPPA TRADING PTE. LTD.85 Kaki Bukit Avenue , Shun Li Industrial ParkSINGAPORE 417955 - SingaporeTel.: +65 8415151 • Fax: +65 [email protected]

OFFICIAL DISTRIBUTOR ALSO FOR:MALAYSIA - INDONESIA - BRUNEI - THAILAND

USA SOUTH AMERICA

MARZOCCHI USA25213 Anza Drive – VALENCIA - CA 91355 USATel.: +1 661 257 6630 • Fax: +1 661 257 [email protected] • www.marzocchi.com

Marzzochi Shiver DC Manual

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