User manual MARZOCCHI 2005 BOMBER

[. . . ] USE OF THE MANUAL 8 · Carefully read, understand and follow the instructions given in this manual. This manual is an essential part of the product, and you should keep it in a safe place for future reference. 1 · If the use and maintenance instructions provided in this manual are not properly performed, or if the other instructions in this manual are not followed, an accident could occur, resulting in an accident, serious injury or death. · This manual does not explain how to assemble/disassemble the fork from the bicycle, the wheel, the steering set or any other component directly or indirectly associated with the fork that are not actually a part of the fork. · Please be advised that suspension system installation and repair requires specialized knowledge, tools and experience. [. . . ] · By using the 4 mm Allen key tighten the bolts (8A) with the sequence 1-2-3-2-1 to the required torque (6±1Nm). 8B 8A 8A 8C 6 mm 109 15±1 Nm 8D 5 mm 10±1 Nm 8E 4 mm 6±1 Nm MZ024008 8A 8A Picture 8 - Wheel installation on Monster series forks MZ024 English 3 Installation 3. 5 Fender Installing Picture 9 8 mm A fender may be installed on the 66, 888, All Mountain, Junior T, Z1 FR models. The fender can be provided with the fork or purchased separately. When assembling the fender (9A) you must insert the small support bushing (9B) between the screw and the fender as shown in the picture, and tighten the screws (9C) with a 8 mm Allen wrench to the required torque (6±1Nm). 6±1 Nm 9A 9B 9C Picture 9 - Fender Installing 3 110 3. 6 Handlebar clamp installing The dual crown models can be provided with handlebar clamp (the handlebar clamp may be sold together with the fork or purchased separately). MZ024009 MZ025013 Picture 10 - Handelbar clamp installing MZ024 English 5 mm 10±1 Nm 3. 6. 1 Handlebar clamp installing on all dual crown models except the 888 series Picture 10 10A 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. · Lock the handlebar with the appropriate clamp (10C). · Tighten the screws (10D) to the required torque (10±1 Nm), using a 5 mm Allen key. You can find reduction shells (10E) as a spare part if needed, to allow installation of handlebars having different diameter. 10B 5 mm 10±1 Nm 10E 10D 10C Installation 3. 6. 2 Handlebar clamp installing on 888 series Picture 11 4 mm For the installation please carefully follow these instructions: · Install the handlebar lower mounting (11A) on the upper crown, in a way that the holes coincide. · Fix the handlebar clamp by tightening the 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. 11A 6±1 Nm 11B 4 mm 6±1 Nm 11E 11D 111 11D 11C 11C MZ024011 Picture 11 - Handlebar clamp installingon 888 series forks MZ024 English 3 Maintenance 4 4 6 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 MARZOCCHI authorized centres. Table 4. 1: Problems - Diagnosis - Solutions must be performed only by Problem Diagnosis Solution Increase spring preload Add spring preload by replacing the preload tube 112 MZ024 English 4 Fork has too much sag Spring rate too soft or fork oil too fluid Check the oil level Change to stiffer spring rate Increase air pressure Increase compression damping by changing oil level Increase compression damping through the proper adjuster Check oil level Forks bottoms too easily, but it has the recommended sag Not enough compression damping Fork bottoms too easily; needs more than maximum preload Spring rate too soft or fork oil too fluid Install stiffer springs Increase air pressure Check oil level Fork does not get full travel Spring rate too stiff or fork oil level too high Install softer spring Decrease air pressure Fork extends too quickly; harsh top-out after impacts Fork bottoms out too quickly Front wheel wants to tuck under while cornering Not enough rebound damping Not enough compression damping Too much rebound damping; spring rate too soft Increase rebound damping Replace oil (SAE 7, 5) with a higher viscosity Increase compression damping at the travel end via the proper adjuster Decrease the rebound damping Increase spring rate Maintenance Problem Diagnosis Solution Decrease rebound damping Decrease rebound damping Replace all seals Replace all seals and have the stanchions inspected Replace all seals Tighten bottom nut/screw Replace O-ring Replace sliding bushings Change oil Contact a service center to verify the correct fork's function English Fork "packs up" or stays down in travel during multiple Too much rebound damping impacts Knocking sound during Too much rebound damping rebound, but no harsh top-out Oil "ring" on stanchions Heavy amount of oil on stanchions; oil dripping down legs Fork is sticky; fork does not perform as new Oil leakage from the bottom Oil seals are contaminated Seals are damaged, stanchions could be damaged Oil seals are contaminated; fork needs to be serviced Loose bottom nut/screw O-ring damaged Worn sliding bushings Loss of sensitivity Old oil Unusual soundscoming from the TAS cartridge The TAS control knob turns during use 4 113 TAS cartridge is damaged WARNING!The operations listed below accompanied by this symbol MARZOCCHI authorized centres. Table 4. 2: Periodic maintenance table must be performed only by General maintenance operation Check that screws are tightened to required torque Stanchions cleaning Air pressure control Air bleed (Monster T) Oil seals control Fork oil change TST Cartridge oil change Fork's oil seals replacement / TST Cartridge / DOPPIO AIR Cartridge Use Intense Before every ride After every ride Before every ride Before every ride 25 hours 50 hours 25 hours 50 hours 10 hours 10 hours 50 hours 100 hours 50 hours 100 hours Normal MZ024 Maintenance 4. 2 General maintenance recommendations · After disassembling the forks, always use new, original Marzocchi seals when reassembling. · To tighten two bolts or nuts that are near each other, always follow the sequence 1-2-1, and tighten to the required tightening torque (see Table 6. 14 - Tightening torques). · Never use flammable or corrosive solvents to clean the parts, as these could damage the seals. If you must use a solvent, use biodegradable detergents that are not corrosive, not flammable or have a high flash point · If you are planning not to use your fork for a long period of time, always lubricate the fork's components that are in contact with the fork's oil. · Never pour lubricants, solvents or detergents which are not completely biodegradable in the environment; these must be collected and kept in the appropriate containers, then disposed of according to local laws. · All of the components of Marzocchi forks are metric. Use only metric tools, imperial (US) tools may have similar sizes, but can damage the bolts and make it impossible to unscrew them. [. . . ] The foregoing statements of warranty are exclusive and lieu of all other remedies. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation or exclusion may not apply to you. DISCLAIMER. ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL IMPLIED WARRANTIES ARISING FROM A COURSE MARZOCCHI distributors and service centers EN You can find the updated distributors list on the Internet page www. marzocchi. com MZ024 281 Marzocchi distributors and service centers MARZOCCHI DISTRIBUTORS AND SERVICE CENTERS EUROPE COUNTRY COMPANY TRENDSPORT GmbH Südtirolerstr. , 1 - A6911 LOCHAU ­ Austria Contact: Mr. Klaus Froeis Tel. : +43 (0)5574 47147 · Fax: +43 (0)5574 52334 Info@trendsport. co. at SCAN BIKE Frichsvej 17 ­ DK-8600 SILKEBORG - Denmark Contact: Lars Munskø Tel. : +45 (0)86 80 54 88 · Fax: +45 (0)86 80 54 75 scan-bike@email. dk OY DUELL BIKE-CENTER AB Porraskuja 3, - 01740 VANTAA ­ Finland Contact: Jussi Laurikainen Tel. : +358 (0)6 322 7500 · Fax: +358 (0)6 322 2231 info@duellbike. fi · www. duellbike. fi PHILAMY S. A. [. . . ]