Marzocchi Bomber 2004 Owner's Manual
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Marzocchi Bomber 2004 Owner's Manual

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  • Page 3 • Check to be sure that all quick release • The lifespan of Marzocchi products depends fasteners, nuts and bolts are properly on many factors, such as riding style and adjusted. Bounce the bicycle on the ground riding conditions.
  • Page 4 PROPERLY well as frames, wheels and other components specifically designed for this riding style. The Marzocchi suspension forks are among the disk brakes must be attached to the designated most durable and technologically advanced mounting points provided on the fork. Never forks on the market today.
  • Page 5 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: 2004 Fork Riding Categories and Intended USE...
  • Page 6 REMEMBER Even 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”...
  • Page 7 Use and maintenance instruction manual...

  • Page 8: Table Of Contents

    Plus fork......... 118 Wheel installing with a QR20 Notes..........141 “With Bolt” fork....... 119 Wheel installing with a 888 Marzocchi distributors and service Series fork ........120 centers..........281 Wheel installing with a Monster Series fork ........121 Wheel installing with a Shiver fork . 122 Fender installing ......
  • Page 9 Table index 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 ........

  • Page 10: Introduction - General Safety Regulations

    MARZOCCHI reserves the right to make have to be followed for both, the MARZOCCHI changes to the products, at any time and without BOMBER forks’ and maintenance.

  • Page 11: Use Application Of The Bomber Forks

    Do not use forks for an application that is You will find in the following table the use different from the one provided by the applications of MY2004 Marzocchi Bomber manufacturer. further information forks. concerning the specific fork’s use, please refer to the “Safety regulations for the user”...

  • Page 12: Technical Information

    2.1 Fork’s external components fender for all models with ø32mm legs and for the new forks of the 888 series. The MY 2004 MARZOCCHI BOMBER forks The fender mounted to the underside of the range includes many different models, having...

  • Page 13: Wheel Axle Securing System

    20 mm axle. The new QR20 Plus 20 mm axle system is Marzocchi Bomber wheel axle securing systems: (A) traditional advanced dropout, (B) QR20 Plus, (C) QR20 With Bolt, (D) Shiver dedicated axle, (E) Monster dedicated axle, (F) 888 dedicated...
  • Page 14 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 15 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 16 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 17 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 18 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 19 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 20 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 21 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 22 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 23 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 24 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.
  • Page 25 = option = not available ATTENTION Marzocchi reserves the right to modify data and features quoted in the table here above, if needed for technical and/or commercial requirements. The dimensions indicated in the drawing are only given as indicative. Please check on the internet page www.marzocchi.com for updated information.

  • Page 26: Fork's Internal Components And Fork's Operation

    The moving valve on the shaft controls rebound Inside MARZOCCHI forks you will find coil and low-speed compression damping. The springs or air as a spring system. special valve in the bottom of the cartridge...
  • Page 27 Technical information Table 14: BOMBER forks damping systems Damping system Fork Right leg Left leg Dirt 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...

  • Page 28: Installation

    Improper installation jeopardize the safety of the rider. Marzocchi does guarantee installation and refuses all responsibility for bottom face of the steering crown shall be damages and/or accidents that may be greater than 4 mm. caused by an incorrect installation.

  • Page 29: Installing The Brake System

    (models for 29" wheel and Z1 Wedge), bolts (A) are not only used to fix the V- ATTENTION brake levers; they also contribute to lock Marzocchi does guarantee the upper part of the slider to the arch. In installation and accepts no liability for...

  • Page 30: Wheel Installing With A Standard Fork's End

    Installation 3.3 Wheel installing with a standard fork’s end ATTENTION Install the wheel in compliance with the manufacturer’s instructions. For correct fork function after wheel installing you will need to: • check the correct fork-wheel alignment by fully compressing the fork a few times. •...

  • Page 31: Wheel Installing With A Qr20 "With Bolt" Fork

    Installation 3.5 Wheel installing with a QR20 “With 6 mm Bolt” fork For correct fork function, please follow the instructions here below when installing the wheel: • Using a 6 mm Allen key unscrew both screws (L) as much as needed to open the securing device (M) •...

  • Page 32: Wheel Installing With A 888 Series Fork

    Installation 3.6 Wheel installing with a 888 Series fork For correct fork function, please follow the instructions here below when installing the wheel: • Insert the wheel axle (A) through the right wheel axle clamp, the wheel and the left wheel axle clamp.

  • Page 33: Wheel Installing With A Monster Series Fork

    Installation 3.7 Wheel installing with a Monster 4 mm Series fork 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 (E) holding the arch (D) by means of a 4 mm Allen key.

  • Page 34: Wheel Installing With A Shiver Fork

    Installation 3.8 Wheel installing with a Shiver fork For correct fork function, please follow the instructions here below when installing the wheel: • Insert the wheel axle (A) through the right wheel axle clamp, the wheel and the left wheel axle clamp. •...

  • Page 35: Maintenance

    Fork “packs up” or stays down in travel Too much rebound damping Decrease rebound damping during multiple impacts Knocking sound during rebound, but Too much rebound damping Decrease rebound damping no harsh top-out Operations to be carried out at MARZOCCHI authorized centres...
  • Page 36 Replace O-ring Worn sliding bushings Replace sliding bushings Loss of sensitivity Old oil Change oil Operations to be carried out at MARZOCCHI authorized centres Table 16: Periodical maintenance table General maintenance operation Intense Normal Check screws tightening up Before every ride...

  • Page 37: General Safety Regulations

    If this is not • After a complete breakdown, always use new, the case, or if you are unsure, please contact original Marzocchi seals when reassembling. authorized service center,...

  • Page 38: Cleaning The Fork Legs

    Maintenance 4.3 Cleaning the fork legs NOTE 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 suspension system, such grease can melt and stick to the stanchions, looking like an oil leak, although it is not.

  • Page 39: Air Bleeding

    Maintenance 4.4 Air Bleeding 2 mm NOTE This operation must be carried out with the fork assembled on the bicycle and with the fork’s legs fully extended (front wheel off the ground). NOTE The pressure generated by the air that can get into the fork legs while the bike is being used and which, due to the special shape of the oil seals remains trapped inside, can cause the...

  • Page 40: Adjustments

    Adjustments ADJUSTMENTS ATTENTION Please visit our web site www.marzocchi.com for any information concerning the travel increase kit and for different spring rates (K). Table 17: MY04 adjustments table Fork PLe PLmi REBC ECA EHSC ECC5 ETA Dirt Jumper I Dirt Jumper II...

  • Page 41: Preload

    Adjustments Table 18: Legend External Preload Spring preload with external adjuster PLmi Internal mechanic Preload Spring preload with internal mechanical adjuster Internal Preload Internal Preload Positive Air Preload Positive Air Preload Negative Air Preload Negative Air Preload REBC Rebound cartridge Rebound Cartridge External Compression Adjust External Compression Adjust...

  • Page 42: Spring Preload With Internal Adjustment

    Adjustments 5.1.2 Spring preload with internal adjustment NOTE The fork is set to the minimum preload by the manufacturer, i.e. the adjuster is completely turned counterclockwise. However, the spring is slightly preloaded to help counteractining static load. To adjust the initial setting according to the rider’s weight and needs, you will have to remove the plastic protection cap (A) and turn the adjuster (B), using a 4 mm Allen key.

  • Page 43: Internal Spring Preload

    If the pumping rod and more precisely the metallic wire 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. • Lift the stanchions and tighten the fork’s...

  • Page 44: Air Preload

    Adjustments 5.1.4 Air preload ATTENTION To inflate your fork, use only the special MARZOCCHI pump with pressure gauge, which you can buy at the authorized centers. Use of improper tools might lead to improper inflating and cause improper function or damage to the fork itself.

  • Page 45: Negative Air

    5.2 Negative air ATTENTION To inflate your fork, use only the special MARZOCCHI pump with pressure gauge, which you can buy at the authorized centers. Use of improper tools might lead to improper inflating and cause improper function or damage to the fork itself.

  • Page 46: Cartridge Forks Rebound Adjustment

    Adjustments 5.3 Cartridge forks rebound adjustment The extension (or rebound) damping adjustment can be made, according to the models, by rotating the adjustment knob (A) directly, or, where the knob is not available, by acting on the adjustment screw (B), using a proper flat tip screwdriver.

  • Page 47: Rebound Adjustment With External Adjustable Pumping Rod

    Adjustments 5.4 Rebound adjustment with external adjustable pumping rod When turning the adjustment knob (B) located on the bottom of the fork’s leg, you can adjust the damping during the rebound phase. By turning on the adjustment screw you can modify the hydraulic configuration of the inner valves: this means that there will be more or less oil flowing through the valve.

  • Page 48: Compression Adjustment

    Adjustments 5.6 Compression adjustment By acting on the adjustment screw (T), located on bottom of the right leg, you can control the fork’s compression damping. By turning the adjustment screw and using a proper small flat tip screwdriver, you can adjust the hydraulic configuration of the inner valves that control the compression.

  • Page 49: Ecc5

    Adjustments 5.8 ECC5 The ECC5 cartridge offers on-the-fly adjustment of the rebound damping. By turning on the adjuster (A) you can modify the hydraulic configuration of the inner valves, controlling the flow of more or less oil, up to the “LOCK OUT”...

  • Page 50: Tables

    Tables TABLES Table 19: Tightening torques Components to be tightened Tightening Torque (Nm) Wheel axle bolts 15 ± 1 Wheel axle allen bolts 10 ± 1 Fork’s upper caps (all except 888 Series) 20 ± 1 Fork’s upper caps (888 Series) 15 ±...

  • Page 51: Warranty

    WARRANTY parties. The rights of the original purchaser under this warranty may not be assigned. If any component of your Marzocchi Suspension System is found to be defective in materials or 3. TERM. The term of this warranty shall workmanship within the term of this Limited Two commence on the date of purchase and Year Warranty (the “Agreement”), the defective...
  • Page 52 Marzocchi S.p.A. NOTE Purchaser’s sole and exclusive remedy will Thank you for the purchase of this Marzocchi be repair or replacement of defective Suspension System. If any defect covered materials as stated above. No dealer and no under the warranty appears with the agreed...

  • Page 53: Notes

    Notes NOTES ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 54: Marzocchi Distributors And Service Centers

    MARZOCCHI distributors service centers...
  • Page 55 Marzocchi distributors and service centers MARZOCCHI DISTRIBUTORS AND SERVICE CENTERS EUROPE COUNTRY COMPANY 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 RAKBIKE S.A. Avenue Jeanne 13 – 1050 IXELLES - Belgium...
  • Page 56 Marzocchi distributors and service centers TAVARES & TIMMERMANS, Lda. Bike Center Condomínio Industrial de Alcolombal – Estrada de Alcolombal, Armazém 1 2705-833 TERRUGEM-SINTRA – Portugal PORTUGAL Contact: Hans Timmermans Tel. +351 (0)21 961 06 21 • Fax +351 (0)21 961 06 38 bkecenter@mail.telepac.pt •...
  • Page 57 Marzocchi distributors and service centers OTHER COUNTRIES COUNTRY COMPANY GROUPE SPORTIF PTY. LTD. 20 Harker Street, BURWOOD, Victoria 3125 – Australia AUSTRALIA Tel.: +61 3 9888 9882 • Fax: +61 3 9888 9902 help@groupesportif.com • www.groupesportif.com PLINIO CURI IMP. EXP.LTDS Rwa Pamplona 8185 Andar - 01405-030 SAO PAOLO –...

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