User manual MARZOCCHI 2003 MONSTER

[. . . ] 3 ISTRUZIONI PER L'USO E LA MANUTENZIONE USE AND MAINTENANCE INSTRUCTION MANUAL MODE D'EMPLOI ET ENTRETIEN BETRIEBS - UND WARTUNGSANLEITUNG MZ002 INSTRUCCIONES PARA EL USO Y MANTENIMIENTO Español Deutsch Français English MONSTER 2003 Italiano Italiano 22 Important!REMEMBER THAT INCORRECT USE OF THE FORK CAN BE VERY DANGEROUS TO YOUR SAFETY. Carefully read this manual and follow all suggestions that you will find in it. Never use a fork that is damaged in any way (oil leakage, bent or cracked components, etc). [. . . ] Do not use forks for an application that is different from the one provided by the manufacturer. M MONSTER T2 MONSTER TRIPLE SUPER MONSTER English M A-XC XC DJ FR FR-DH A-XC XC DJ FR FR-DH Marathon Enduro: for marathon and cross-country use. Before assembly on the frame, make sure that the lower crown screws are correctly tightened. When the fork's legs are at travel's end, the "D" distance between the lower part of the lower crown and the dust seal must be bigger than 3 mm. The stanchion tubes clamping to the crowns has to be done in the areas where the diameter is bigger. A different position of the crowns could damage the fork and could be causing accidents. 3. 2 Installing the brake system Assembling the brake system is a very delicate operation that must be carried out by specialized personnel. Marzocchi does not guarantee the assembly and refuses all responsibility for damages and/ or accidents that may be caused by an incorrect assembly. Improper installation of the disk brake system can overstress the caliper mountings, which may break. The brake system assembling must be carried out in compliance with brake system's manufacturers instructions. Only use brake systems that are complying with the fork's specifications. MZ002011 MZ002004 Improper installation may jeopardize the safety of the rider. Marzocchi does not guarantee the installation and refuses all responsibility for damages and/or accidents that may be caused by an incorrect assembly. English D > 3 mm The fork is supplied with "A-Head Set" (threadless) steer tube to be cut according to frame size. Installing a MARZOCCHI fork on the bicycle frame is a very delicate operation that must be carried out by specialized personnel. The assembling on the frame and the steer tube adjustment must be carried out in compliance with the headset manufacturer's instructions. MZ002010 H < 190 MZ002 Installation 3. 3 Wheel installing 31 4 mm Install the wheel in compliance with the bicycle manufacturer's instructions. For correct fork 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 in 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 hex key. MZ002019 D E E · By using a 6 mm hex key, tighten the axle bolt (B) located on the left side to the required torque (see Table 1 - Tightening Torques). · By using the 5 mm hex key, tighten the bolts (C) positioned on both dropouts to the required torque (see Table 1 - Tightening Torques), with the 1-2-1 sequence. · By using the 4 mm hex key, tighten the bolts (E) with the sequence 1-2-3-2-1 to the required torque (see Table 1 - Tightening Torques). MZ002005 A Incorrect wheel alignment can misalign the legs make them unparallel, causing the fork to bind. 5 mm 6 mm B MZ002 MZ002007 MZ002006 C C English · Insert the wheel axle (A) through the right wheel axle clamp, then the wheel and the left wheel axle clamp. 32 Maintenance MAINTENANCE Problems - Diagnosis - Solutions 4 4. 1 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. Operations inside the grey box must be carried out by authorized service centers. Problem Diagnosis Solution Add spring preload by replacing the preload sleeve Check oil height Change to stiffer spring rate Forks bottoms too easily, but it has the recommended sag Not enough compression damping Increase compression damping by changing oil level Increase compression damping* Check oil height; bottom out compression adjuster Get softer spring Decrease compression damping* Fork bottoms out easily Not enough compression damping Increase high speed compression damping via the proper adjuster Increase rebound damping* Replace oil (SAE 7, 5) with a higher viscosity Decrease the rebound damping* Change to stiffer spring rate Decrease rebound damping* Bleed the air Decrease rebound damping* Replace all seals (repair the fork before using it again) Replace all seals and have the stanchions inspected (repair the fork before using it again) Replace all seals (repair the fork before using it again) Tighten bottom nut Replace o-ring Replace sliding bushings Change oil English Fork has too much sag Spring rate too soft or oil too fluid Fork does not get full travel Spring rate too stiff or fork oil too high Fork extends too quickly; harsh Not enough rebound damping top-out after impacts Front wheel wants to tuck under Too much rebound damping; while cornering spring rate too soft Fork "packs up" or stays down Too much rebound damping in travel during multiple impacts Loss of fork's smoothness Knocking sound during 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 of the leg Loss of sensitivity Presence of air inside the legs Too much rebound damping Oil seals are contaminated Seals are damaged, stanchions could be damaged Oil seals are contaminated; fork needs to be serviced Loose bottom nut Bottom nut o-ring damaged Worn bushings Old oil *This operation cannot be carried out on the Monster T2 model. MZ002 Maintenance 4. 2 Periodical maintenance table Use Intense After every ride 50 hours 50 hours 100 hours 100 hours Normal 33 General maintenance operation Clean stanchions and dust seals Oil change Oil seals replacement 4. 3 General safety regulations After a complete breakdown, always use new seals when reassembling. To tighten two bolts or nuts that are near each other, always follow the sequence 1-2-1 using the required tightening torque (see Table 1 - Tightening Torques). Never use flammable or corrosive solvents to clean the parts, as these could damage the seals. If necessary, use specific detergents that are not corrosive, not flammable or have a high flash point, compatible with the seals materials and preferably biodegradable. 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