Marzocchi BOMBER 2005 Owner's Manual
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Marzocchi BOMBER 2005 Owner's Manual

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  • Page 3 • If the use and maintenance instructions • The lifespan of Marzocchi products depends provided in this manual are not properly on many factors, such as riding style and performed, or if the other instructions in this riding conditions.
  • Page 4 RIDE make any modification to your fork to attach any equipment. PROPERLY Marzocchi suspension forks are among the FreeRide (FR): This riding style is for skilled most durable and technologically advanced riders and involves aggressive slopes, large forks on the market today. However, no fork can obstacles, and moderate jumps.
  • Page 5 “drops” and negotiating larger obstacles such as 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 selecting the correct fork. Tab 1:...
  • Page 6 Certified Marzocchi forces generated during the landing, and both Repair Center inspect the forks before you wheels should smoothly make contact with the ride again.
  • Page 7 Use and maintenance instruction manual...

  • Page 8: Table Of Contents

    Wheel axle securing system..105 Warranty .......... 140 3.4.1 Wheel installation on a standard fork’s end ....106 Marzocchi distributors and service centers..........281 3.4.2 Wheel installation on ø 32 mm forks with ø 20 mm through hole axle ........106 3.4.3...
  • Page 9 Table index TABLE INDEX Table 2.1: Spring systems ......99 Table 2.2: Damping systems ..... 100 Table 3.1: Steer tube maximum length between crowns......103 Table 3.2: Brake system settings ....104 Table 3.3: Maximum wheel dimension ..105 Table 4.1: Problems - Diagnosis - Solutions........

  • Page 10: Introduction-General Safety Regulations

    MARZOCCHI reserves the right, in its sole directly. A list of service centers can be found at discretion, to make changes to the products, at the end of this manual or on the Internet page any time and without prior notice.

  • Page 11: Technical Information

    Technical information TECHNICAL INFORMATION Spring systems Inside MARZOCCHI forks you will find coil springs or air as a spring system. Table 2.1: Spring systems Spring systems Right leg Left leg MX Comp Air MX Comp Coil Coil spring MX Comp ETA...

  • Page 12: Damping System

    Technical information 2.2 Damping system The damping load that is generated during the fork legs compression and rebound can be adjusted by hydraulic valve pumping rods, or by special cartridges. Table 2.1: Damping systems Damping systems Right leg Left leg SSV damping rod with rebound MX Comp Air Not adjustable SSV damping rod...
  • Page 13 Technical information Spring systems Right leg Left leg HSCV cartridge with rebound HSCV cartridge with compression 66 RC outside adjustment outside adjustment at travel end HSCV cartridge with rebound 66 R Not adjustable SSV damping rod outside adjustment 66 VF Pompante SSVF non regolabile HSCV cartridge with rebound HSCV cartridge with compression...

  • Page 14: Lubrication And Cooling

    Technical information 2.3 Lubrication and cooling 2.4 Sliding bushing and oil seals Pumping rods are immersed in oil (Open Bath Stanchion tubes are guided in the sliders by two System). This system provides proper teflon-coated bushings, free from static friction. lubrication and cooling of the inner sliding parts;...

  • Page 15: Installation

    Marzocchi Suspension Center. Improper installation can result in failure of your Marzocchi Suspension System, an accident, personal injury or death. The steer tube must be press fit into the crown. Picture 2 - Dual crown forks installation on the frame:...

  • Page 16: Installazione Dell'impianto Freno

    Please have your brake system installed only by an authorized Marzocchi Service Center. In particular, improper installation of a disk brake system can overstress the caliper mountings, which Table 3.1: Brake system settings...

  • Page 17: Wheel Installation

    Installation WARNING! WARNING! Don’t forget that a special thread-lock The brake cable shall never touch the crown treatment is applied to the bolts thread (3A) ; and stanchions. bolts which are installed and then removed lose this treatment and therefore may never be used again.

  • Page 18: Wheel Installation On A Standard Fork's End

    Installation 3.4.1 Wheel installation on a standard fork’s end Install the wheel in compliance with the manufacturer’s instructions. For correct fork function after installing the wheel you will need to: • Check fork-wheel alignment fully compressing the fork a few times. The wheel should not make contact with or come close to any portion of the fork.

  • Page 19: Wheel Installation On 66 And 888 Series Forks

    Installation 3.4.3 Wheel installation on 66 and 888 series forks Picture 6 For correct fork function, please follow the instructions here below when installing the wheel: • Insert the axle (6A) through the right fork wheel axle clamp, the wheel and the left fork wheel axle clamp.

  • Page 20: Wheel Installation On Shiver Series Forks

    Installation 3.4.4 Wheel installation on Shiver series forks Picture 7 For correct fork function, please follow the instructions here below when installing the wheel: • Insert the wheel axle (7A) through the right wheel axle clamp, the wheel and the left wheel axle clamp.

  • Page 21: Wheel Installation On Monster Series Forks

    Installation 3.4.5 Wheel installation on Monster 4 mm series forks Picture 8 For a correct fork’s function, please follow the instructions here below when installing the wheel. • In case the fork has been disassembled from the bike frame or the fork’s legs position as to the crowns has been changed, you will have to slightly loose the 6 bolts (8A) holding the arch (8B) by means of a 4 mm Allen key.

  • Page 22: Fender Installing

    Installation 3.5 Fender Installing 8 mm Picture 9 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 6±1 Nm 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...

  • Page 23: Handlebar Clamp Installing On 888 Series

    Installation 3.6.2 Handlebar clamp installing on 888 4 mm series Picture 11 For the installation please carefully follow these instructions: 6±1 Nm • Install the handlebar lower mounting (11A) on the upper crown, in a way that the holes coincide. •...

  • Page 24: Maintenance

    Always check this table before working on the fork. WARNING! The operations listed below accompanied by this symbol must be performed only by MARZOCCHI authorized centres. Table 4.1: Problems - Diagnosis - Solutions Problem Diagnosis Solution...
  • Page 25 The TAS control knob turns during use WARNING! The operations listed below accompanied by this symbol must be performed only by MARZOCCHI authorized centres. Table 4.2: Periodic maintenance table General maintenance operation Intense Normal Check that screws are...

  • Page 26: General Maintenance Recommendations

    “polishing compound” to be disposed of according to local laws. kept as bright as new. • All of the components of Marzocchi forks are • Carefully check there are no metal shavings metric. Use only metric tools, imperial (US) or dust in the work area.

  • Page 27: Cleaning The Fork Legs

    Maintenance 4.3 Cleaning the fork legs The manufacturer lubricates the fork dust seal with some grease, which makes the stanchion tubes slide easier, especially when the fork has not been used for a long time. When using the fork, such grease can melt and stick to the stanchions, looking like an oil leak, although it is not.

  • Page 28: Adjustments

    (K) please visit our web page: system. In this paragraph you will find how to www.marzocchi.com. carry out a correct setting of Marzocchi forks. In order to find the best setting you will need to try several times to understand where and how 5.2 Spring preload...

  • Page 29: Sag

    Adjustments The SAG corresponds to the fork’s sinking due to the rider’s weight. How to measure it Picture 13 In order to measure the SAG you only need to carry out following steps: Measure the fork’s leg portion between the lower crown and the dust seal and take note of the value (A).

  • Page 30: Negative Air

    Adjustments 5.4 Negative air 5.7 Compression adjustment If you inflate pressurized air through the valve, You can control the compression speed through you can reduce the fork’s static load. the compression adjuster. By increasing the pressure inside the fork’s leg, The compression adjustment can be done you increase the force helping the fork to start according to the user’s needs and it must...

  • Page 31: Tas (Travel Adjustment System)

    Adjustments 5.9 TAS (Travel Adjustment System) 5.10 TST (Terrain Selection Tecnology) The TAS cartridge offers, in addition to the The TST system allows adjustment of the possibility to adjust “on the fly” the rebound suspension damping. damping, by reducing the fork’s travel, still The TST cartridge is provided, in the lower area, keeping 30 mm- travel (see par.
  • Page 32 Adjustments Table 5.2: Forks adjustments Adjustments MX Comp X2° LH° Tab.6.2 MX Pro X2° LH° Marathon RACE Tab.6.3 Marathon SL Marathon XC All Mountain SL All Mountain 1 Tab.6.4 All Mountain 2 X2° RH RH° LH° All Mountain 3 X2° LH°...

  • Page 33: Summarizing Tables

    0 - 30 0 - 1,00 Preload air pressure 0 - 15 Option Setting operations Air pressure summarizing table Concerned models WARNING! Marzocchi reserves the right to modify data and features indicated in the tables with or without prior notice.
  • Page 34 Summarizing tables Table 6.2: Mx Series MX Comp Air 85 - 105 - 120 INTL STD 6" V-Brake removable setting MX Comp Coil 85 - 105 - 120 INTL STD 6" V-Brake removable setting MX Comp + ETA 85 - 105 - 120 INTL STD 6"...
  • Page 35 Summarizing tables Mx Series MX Comp Air MX Comp Coil MX Comp +ETA Rebound adjustment with internal register – Right leg Using a small pointed object fully deflate the right leg pressure. Fully unscrew and remove the cap using a 21 mm Allen key. Insert the supplied hexagon rod into the stanchion tube, making sure to center the adjustment seat.
  • Page 36 Summarizing tables Table 6.3: Marathon Series Marathon Marathon Race INTL STD 6" V-Brake fixed setting 100 - 120 * Marathon SL INTL STD 6" V-Brake removable setting Marathon XC 100 - 120** INTL STD 6" V-Brake removable setting * adjustable via TAS 30 mm 2,2"...
  • Page 37 Summarizing tables Marathon Series Marathon Race Marathon SL Marathon XC Rebound adjustment with external register - Right leg (Left leg on Marathon Race) When turning the adjuster clockwise, you increase the rebound hydraulic braking, making the fork slower during the rebound phase. When turning the adjuster counterclockwise, you decrease the rebound hydraulic braking, making the fork more responsive during the rebound phase.
  • Page 38 Summarizing tables Table 6.4: All Mountain Series All Mountain All Mountain SL 110 - 130 ** / 130 - 150 ** INTL STD 6" * All Mountain 1 110 - 130 *** / 130 - 150 *** INTL STD 6" * All Mountain 2 110 - 130 -150 INTL STD 6"...
  • Page 39 Summarizing tables All Mountain Series All Mountain 2 HSCV Cartridge – Positive air Remove the rubber protection cap marked with “AIR” and turn the rebound adjustment knob until you uncover the air valve. Fully tighten the pump adapter on the valve and inflate air to the required pressure.
  • Page 40 Summarizing tables All Mountain Series All Mountain SL All Mountain 2 (Travel130 mm) Rebound adjustment with external register – Right leg When turning the adjuster clockwise, you increase the rebound hydraulic braking, making the fork slower during the rebound phase. When turning the adjuster counterclockwise, you decrease the rebound hydraulic braking, making the fork more responsive during the rebound phase.
  • Page 41 Summarizing tables All Mountain Series All Mountain 1 TAS – Left leg By turning clockwise, you will reduce the maximum travel and the fork’s length. By turning counterclockwise, you will increase the maximum travel and the fork’s length. Before proceeding to the TAS cartridge adjustment, you will have to completely deflate the positive air chamber located on the right leg, then re-establish the correct working pressure.
  • Page 42 Summarizing tables Table 6.5: Dirt Jumper Series Dirt Jumper Dirt Jumper 1 100 - 120 ø 20 mm through hole axle INTL STD 6" * Dirt Jumper 2 ø 20 mm through hole axle INTL STD 6" * Dirt Jumper 3 100 - 130 STD ** INTL STD 6"...
  • Page 43 Summarizing tables Table 6.6: D-Street 24”” D-Street 24" ø 20 mm through hole axle INTL STD 6" * V-Brake ** * the 8” brake system installation is allowed using an adapter provided by the brake system manufacturer 32 mm 2,5" x 24" ** Removable setting Spring preload with air (both legs) Remove the protection cap.
  • Page 44 Summarizing tables Table 6.7: Z1 FR Series Z1 FR Z1 FR SL 130 -150 ** ø 20 mm through hole axle INTL STD 6" * Z1 FR 1 130 -150 ø 20 mm through hole axle INTL STD 6" * Z1 FR 2 130 -150 ø...
  • Page 45 Summarizing tables Z1 FR Series Z1 FR 1 Z1 FR 2 Spring preload with air – HSCV cartridge Remove the rubber protection cap marked with “AIR” and turn the rebound adjustment knob until you uncover the air valve. Fully tighten the pump adapter on the valve and inflate air to the required pressure.
  • Page 46 Summarizing tables Z1 FR Series Z1 FR SL TST – Right leg When turning the knob you can adjust the compression damping to adapt the fork’s behaviour to the kind of trail. Best setting for downhill. - , AM , + Best setting for All mountain.
  • Page 47 Summarizing tables Table 6.8: 66 Series 66 RC 150 - 170 ø 20 mm through hole axle INTL STD 6" * 66 R 150 - 170 ø 20 mm through hole axle INTL STD 6" * 66 VF 150 - 170 ø...
  • Page 48 If the pumping rod and more precisely the metallic wire (C) are even slightly damaged, do not use the fork in any case and immediately contact a Marzocchi authorized service centre. Do not alter the metallic wire.
  • Page 49 Summarizing tables Table 6.10: Junior T Junior T STD ** INTL STD 6" * * the 8” brake system installation is allowed using an adapter provided by the brake system manufacturer 32 mm 2,8" x 26" ** ø20 mm through hole axle available as option Spring preload with external adjustment –...
  • Page 50 Summarizing tables Table 6.12: Shiver SC Shiver SC ø 20 mm through hole axle INTL STD 6" * * the 8” brake system installation is allowed using an adapter provided by the brake system manufacturer 30mm 2,8" x 26" Spring preload with external adjustment – Both legs By turning the adjustment knob clockwise, you increase the preload value.
  • Page 51 Summarizing tables Table 6.14: Tightening torques Tightening Torque Components to be tightened (Nm) Wheel axle bolts 15 ± 1 Wheel axle Allen clamping bolts 6 ± 1 Wheel axle Allen clamping bolts (D-Street – Shiver Series – Monster T) 10 ± 1 Fork’s upper caps 10 ±...

  • Page 52: Warranty

    Year Warranty (the “Agreement”), the defective warranty may not be assigned. component will be repaired or replaced, at the option of Marzocchi S.p.A., free of charge, within thirty (30) days after receipt of the Suspension TERM. The term of this warranty shall...
  • Page 53 Purchaser with respect to this purchase. In APPLICABLE LAW. Any disputes arising out of the event of any alleged breach of any warranty this agreement or the use of this Marzocchi or any legal action brought by the purchaser Suspension System will be governed by the...

  • Page 54: Marzocchi Distributors And Service Centers

    MARZOCCHI distributors service centers You can find the updated distributors list on the Internet page www.marzocchi.com...
  • Page 55 Marzocchi distributors and service centers MARZOCCHI DISTRIBUTORS AND SERVICE CENTERS EUROPE COUNTRY C O M P A N Y TRENDSPORT GmbH Südtirolerstr., 1 - A6911 LOCHAU – Austria AUSTRIA Contact: Mr. Klaus Froeis Tel.: +43 (0)5574 47147 • Fax: +43 (0)5574 52334 Info@trendsport.co.at...
  • Page 56 Marzocchi distributors and service centers TAVARES & TIMMERMANS, Lda. Bike Center Condomínio Industrial de Alcolombal – Estrada de Alcolombal, Armazém 1 PORTUGAL 2705-833 TERRUGEM-SINTRA – Portugal Contact: Hans Timmermans Tel. +351 (0)21 961 06 21 • Fax +351 (0)21 961 06 38 bikecenter@mail.telepac.pt •...
  • Page 57 Marzocchi distributors and service centers OTHER COUNTRIES COUNTRY C O M P A N Y GROUPE SPORTIF PTY. LTD. 27 Ceylon Street, NUNAWADING 3131, Victoria – Australia AUSTRALIA Tel.: +61 3 9888 9882 • Fax: +61 3 9888 9902 help@groupesportif.com • www.groupesportif.com PLINIO CURI IMP.
  • Page 59 Cod. 9001060...

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