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Summary of Contents for Marzocchi Shiver DC 2005
- Page 1 © Marzocchi Suspension 2005 - Shiver DC 2005 - Shiver DC Technical instructions...
- Page 2 © Marzocchi Suspension 2005 - Shiver DC Exploded view - Shiver DC 190 Rif. Code Quantity 1 532756>A 2 528050 3 520308PN 4 819310/R 5 5321081 6 528223 7 523286>A 8 5181117>A 9 521142IW>A 10 532810>A 11 528214 12 703639AQ/C...
- Page 3 © Marzocchi Suspension 2005 - Shiver DC Spare part list - Shiver DC 190 Q.ty in the Rif. Code Description model 532756>A FOOT NUT GROUP 528050 O-RING 520308PN SCREW 819310/R RH STANCH+DROP OUT SHIV.DC 05 5321081 INNER ROD 528223 O-RING 523286>A...
- Page 4 © Marzocchi Suspension 2005 - Shiver DC 547633 LH+RH GUARD LABELS SHIV.DC 05 531067 BUFFER 520264AC IN CAP AXLE...
- Page 5 © Marzocchi Suspension 2005 - Shiver DC Technical characteristics: Technical characteristics Dual-crown fork with ø35mm reverse legs. Available travels: 190 mm. Right fork leg damping element: spring with preload mechanical adjustment. Left fork leg damping element: spring with preload mechanical adjustment.
- Page 6 Always grease the seal lips before reassembling. All of the components of Marzocchi forks require the use of metric tools. Use only metric tools. Imperial (US) tools may have similar sizes, but can damage the bolts, making them impossible to loosen or tighten.
- Page 7 © Marzocchi Suspension 2005 - Shiver DC Install the fork onto the frame already equipped with steering set. Install the top crown onto the sliders and the steer tube. Check that the top face (C) is lined up with or above the innermost point of contact (D) between top crown and sliders.
- Page 8 Warnings: Installing the disk brake Installing the brake system is a delicate and critical operation that must be carried out by an authorized Marzocchi Service Center. Marzocchi is not responsible for the installation and accepts no liability for damage and/or accidents arising from this operation.
- Page 9 © Marzocchi Suspension 2005 - Shiver DC Warnings: Installing the handlebar mount For a correct installation of the handlebar mount, follow the instructions below: Install the bottom handlebar mount (1) onto the top crown so that the fixing holes match.
- Page 10 © Marzocchi Suspension 2005 - Shiver DC Dismantling: Removing the top caps Put the fork in the vice in vertical position, fixing it by the dropouts. With a 1.5mm Allen wrench loosen the grubscrew (4) and remove the adjusting knob (5).
- Page 11 © Marzocchi Suspension 2005 - Shiver DC Free the fork from the vice and tip it into a container of a suitable size to drain the oil; compress the fork a few times to help the oil flow out. Do not pour used oils on the ground.
- Page 12 © Marzocchi Suspension 2005 - Shiver DC Remove the threaded pin (2) and locknut (1). Remove the spring guide tube (7). The HSCV cartridges (5) are sealed through machining and cannot be overhauled. In the case of faults or a malfunctioning, they must be replaced.
- Page 13 © Marzocchi Suspension 2005 - Shiver DC Prize the dust seal (1) off its seat with a small flat-tip screwdriver. Take great care not to damage the internal surfaces of the slider while removing the dust seal. With the same screwdriver, prize off the metal stop ring (2).
- Page 14 © Marzocchi Suspension 2005 - Shiver DC The old sealing rings and dust seals must not be used again. To remove the bottom guide bush (7), spacer (8) and the top guide bush (9), knock the end of the slider against a wooden surface.
- Page 15 © Marzocchi Suspension 2005 - Shiver DC Assembling: Reassembling stanchion tube, slider and sealing rings Fit the top guide bush (9). With the help of spacer (8) press the top bush into the slider. Insert the bottom guide bush (7) in its seat.
- Page 16 © Marzocchi Suspension 2005 - Shiver DC Re-assemble the dust seal (1) in its seat, pressing it home with your hands. Assembling: During the assembly of the pumping unit, strictly obey the instructions below. Do not, at any times, reverse the position of the pumping elements in the fork legs (if you are unsure about anything, please refer to the relevant exploded view).
- Page 17 © Marzocchi Suspension 2005 - Shiver DC Tighten the threaded pin (2) on the cartridge rod being careful not to damage the O-ring. With the 10mm and 7.5mm spanners, tighten locknut (1) on the threaded pin (2) to the recommended tightening torque (6 Nm ±...
- Page 18 © Marzocchi Suspension 2005 - Shiver DC In a graduated recipient, prepare the quantity of oil to pour into the fork leg (see table). Pour roughly 1/3 of the oil required into each stanchion, then pump the fork a few times to eliminate any traces of air.
- Page 19 © Marzocchi Suspension 2005 - Shiver DC Fit lock cap (1) and, with a 21mm socket spanner, tighten to the recommended tightening torque (10 Nm ± 1). Mount the stop ring (8). Mount the adjusting knob (5) and, with a 1.5mm Allen wrench, tighten the grubscrew (4) to the...
- Page 20 During setting don't force the adjusters beyond their limit of travel and don't exceed the max recommended air pressure. To keep the pressure inside the fork’s legs, only use the special MARZOCCHI pump with pressure gauge. The use of any other pump can compromise the inflating operation and cause malfunction or damage to the fork, resulting in an accident, personal injury or death.
- Page 21 © Marzocchi Suspension 2005 - Shiver DC Do not force the adjuster beyond its limit of travel. Setting: Rebound adjustment Right fork leg: With the rebound adjuster you can control the return speed of the fork after compression. The right rebound speed setting makes the bike stable letting it follow the variations in the terrain and any obstacles.
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Page 22: Tightening Torques
© Marzocchi Suspension 2005 - Shiver DC Tightening torques Components Tightening torque (Nm) Bottom crown fixing screws 10±1 Fork leg top caps 10±1 Handlebar fixing screws 10±1 Preload knob locking grubscrews 1,5±0,2 Preload knob locknut 6±1 Pumping element/cartridge bottom nuts 10±1... - Page 23 © Marzocchi Suspension 2005 - Shiver DC Diagnostics Finding the problem Finding the possible cause Possible solutions proposed Fork doesn't get full travel Oil level too high Check oil levels Fork extends too quickly; harsh top-out after Rebound damping is not enough...
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