Marin Frs quad-link User manual

FRS QUAD-LINK Service Manual

2004 Edition 1

Marin FRS Quad-Link Service Manual

Page 12 2004 Edition 1

12.0: Rear Suspension Set-up - QUAD-Link FRS - Preload

These bikes are fitted with either a Fox or an X-Fusion rear air shock unit. The air pressure

in the shock determines the spring rate.

The correct ‘sag’ can be found using the sliding ‘o’ ring fitted to the shaft of the shock pis-

ton. Slide the ‘o’ ring against the shock body. Then gently sit on the bike in your normal

riding position. Carefully dismount and measure the distance the ‘o’ ring has moved away

from the shock body.

The optimum distance for the QUAD system is 12mm displacement from the ‘o’ ring

back up to the shock body. If there is less than 12mm fit a shock pump and release air

pressure. Conversely if there is greater than 12mm of travel, fit the shock pump and in-

crease air pressure. Repeat the ‘sag’ test until the 12mm displacement is achieved.

12.1: Rear Suspension Set-up - QUAD-Link FRS - Rebound Damping

When the damper unit is being compressed, this is known as the compression stroke. As

the suspension unit recovers from compression back towards its full length, this is called

the re-bound stroke. All the shocks fitted as standard to Marin QUAD-LINK FRS bikes have

factory set compression damping, and manually adjustable rebound damping.

Rebound Damping adjustment.

This adjustment fine-tunes the speed at which the rear wheel returns to its normal ride

height after hitting a bump. The adjuster is coloured red and is found on the rear damper

unit. An arrow marked slower indicates the direction to turn the dial to slow down the re-

bound speed of the suspension. To demonstrate the effect of this, turn the adjuster to its

slowest setting. Press down on the saddle to compress the suspension, then release the

load. You will see that the suspension recovers very slowly to its original position.

Repeat the above with the adjuster turned to the fastest setting and you will see the

difference immediately the load is released. We recommend the optimum setting is to

adjust the re-bound damping to be as slow as possible, but not so slow that the normal

ride height is not recovered. On very rough terrain, if the rear of the bike becomes

progressively lower as more bumps are hit then the re-bound damping is set too slow. On

the other hand if the bike feels choppy and not plush then the re-bound damping is too

fast. A bit of trial and error is needed to get the exact setting. Riders may choose to

change their settings, while stationary, depending on the terrain they are riding.

13.0: Front Suspension Set-up

When you have set the rear suspension, follow the Owners Manual to fine tune the front

forks. It is important to achieve a balance between the front and rear of the bike. In time,

you will be able to make these small adjustments required to optimise the way in which

the front and rear suspension work together over all types of terrain. In order to achieve

maximum traction, we recommend that it is best to run a small amount of initial “sag” on

the front forks, in the same way as on the rear.

Table of Contents:

1.0 Figure 1, Exploded Diagram: Rear Shock Assembly.

1.1 Parts List: Rear Shock Assembly

2.0 Removal of Rear Shock

3.0 Figure 2, Exploded Diagram: Rear Suspension Assembly

3.1 Parts List: Rear Suspension Assembly

4.0 Removal of Swinging Arm

5.0 Removal of Links

6.0 Figure 3, Exploded Diagram: 1 Piece Link Assembly

6.1 Parts List: 1 Piece Link Assembly

7.0 Figure 4a,4b,4c,4d. Illustration of KP5AX Bearing Extraction

7.1 Extracting KP5AX Bearings from 1 Piece Links

8.0 Figure 5, Illustration of KP5AX Bearing Installation

8.1 Parts List: Assembly of KPAX Bearings for Installation

8.2 Installation of KP5AX Bearings

8.3 Figure 6, Diagram of Centre Spacer Installation

8.4 Parts List: Assembly of Centre Spacer Installation

8.5 Installation of Centre Spacer and Remaining KP5AX Bearing

9.0 Figure 7, Illustration of Assembly of Links to Main Frame

9.1 Fitting of Link Assemblies

10.0 Fitting of Swinging Arm

11.0 Fitting of Rear Shock

12.0 Rear Suspension Set-up: Pre-Load

12.1 Rear Suspension Set-up: Rebound Damping

13.0 Front Suspension Set-up

14.0 Torque Settings

15.0 Notes

Marin FRS Quad-Link Service Manual

Page 1 2004 Edition 1

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Page 1

Marin FRS Quad-Link Service Manual

1.0: Figure 1, Exploded Diagram Rear Shock Assembly.

Page 2 2004 Edition 1

Marin FRS Quad-Link Service Manual

9.1 Fitting of Link Assemblies to Mainframe. Figure 2

Tools Required: 10mmA/F socket with ratchet or T-Bar drive

5mm A/F Allen Key

Torque wrench

The two link assembly’s (3) used on the MARIN QUAD FRS are identical, as are the fitting

procedures, which is basically the reverse of the removal procedure. Both links are fitted to

the bike with the central crosspiece, part of the link, on the bottom of the link assembly, as

illustrated in Figure 7. Carefully slide the link assembly (3) onto the main frame making

sure the shield washers do not drop out. Insert screw (4), (70mm), through the link and

main frame (2) replace nut (5) and torque tighten using the 5mm allen key and torque

wrench. Refer to torque settings in section 14.0

10.0: Fitting of Swinging Arm. Figure 2

Tools Required: 10mmA/F socket with ratchet or T-Bar drive

5mm A/F Allen Key

4mm A/F Allen Key – 2 off

Torque wrench

Offer the swing arm (1) into position with the main frame (2). Align the boss at the front of

the swing arm (1) with the front link assembly (3), making sure the shield washers have

not fallen out. Insert the bolt (6) (85mm), through the washer (7), swing arm (1), main

frame (2), swing arm (1) and washer (7), replace nut (5) and tighten with the torque

wrench. Next align the rear boss in the swing arm (1) with the rear link assembly (3) mak-

ing sure the shield washers have not fallen out. Insert the bolt (6) (85mm), through the

washer (7), swing arm (1), main frame (2), swing arm (1) and washer (7), replace nut (5)

and tighten with the torque wrench. The swing arm (1) should now be fixed to the main

frame (2) and should move freely with no sideways movement. For torque settings, refer

to section 14.0. Remember to re-fit brake assemblies, and check they are functioning cor-

rectly before riding the bike.

11.0: Fitting of Rear Shock. Figure 1

Tools required: 10mm A/F socket with ratchet or T-bar drive x 2

5mm A/F Allen Key

4mm A/F Allen key x 2

Basically this is the reverse of the removal procedure. Ensure that the Top Hat Bushes (9)

are installed into the inside of the mainframe mounting point (2). It is best to loosely as-

semble both ends of the Shock to ensure correct alignment before finally tightening Nut (5)

and Bolts (13). Refer to torque settings in section 14.0. Refit plastic plugs (14)

Page 11 2004 Edition 1

Ensure the KP5AX Bearing (2) and Link (1) surfaces are clean and apply Loctite 641 on the

outside of the KP5AX Bearing (2) and the inside bearing surface of the Link (1). Before

sliding the Center Spacer (3) into position, it is essential that each end of the Center

Spacer (3) has a large amount of MOLYCOAT grease on both ends to create a donut of the

grease. This will then spread and fill the Labyrinth on assembly. Pass the Centre Spacer (3)

though the Link (1), taking care not to contaminate any bearing surfaces, and locate

against the bearing already pressed in. Using an engineers vice with ‘soft jaws’ to prevent

any damage to the Link, align the Bearing Insertion Tool (9) and Bearing (2) to be pressed

into the Link (1) correctly. Press the Bearing (2) into the Link (1), ensuring that the Centre

Spacer (3) is located in both it’s Labyrinth gaps. Remove any excess Molycoat grease from

around the area. Once all the KP5AX bearings (2) and Link Centre Spacer (3) have been

assembled, the final application of lubricants can be applied before assembly into the Bicy-

cle.

Before re-assembling the Shield Washer Components (4) (5) (6), apply large quantities of

Molycoat Grease on top of the KP5AX Bearings (2) seated in the link (1). The grease should

completely cover each bearing and be applied on both sides of the bearing as it is assem-

bled into the Link (1). Next assemble the Shield Washer Components (4) (5) (6). If you

have applied enough Molycoat grease, grease should spread from under the Shield Washer

component as they are positioned. Wipe excess grease away from around the Shield

Washer Components.

Application of SKF LGAF 3 Compound.

Once the Link has been assembled and correctly greased, SKF LGAF 3 Compound

must be applied to all outside faces of the Shield Washer Components (4) (5) (6)

that contact the Main Frame and Swinging Arm. It is additionally suggested to

apply SKF LGAF 3 compound to the link contact surfaces on the Main Frame and

Swinging Arm.

9.0: Figure 7: Installation of Links onto Mainframe.

Marin FRS Quad-Link Service Manual

Page 10 2004 Edition 1

1.1: Parts List, Rear Shock Assembly

No. Description Part Code Qty

1. Frame Shock Mount N/A (Part of Frame) 1

2. M5 x 16 Socket head cap 97-0000 2

3. M5 Washer Supplied with No. 2 2

4. Collar 97-3035 2

5. Shaft 97-3036 1

6. Top Hat bushes TOPHAT2012 2

7. FOX bushes (22mm) FOXBUSH4 2

8. Glacial Bearing FOXBUSH1 1

9. M6 Sleeve 1

10. FOX bushes (35,5mm) FOXBUSH5 2

11. Glacial Bearing FOXBUSH1 1

12. Plastic Plug 97-3032 2

13. M6 Nylock Nut NYLOCKM6 1

14. M6 Flat Washer WASHERM6 1

15. M6 x 55mm Socket Head Cap M6X55 1

2.0: Removal of Rear Shock

Tools required: 10mmA/F socket with ratchet or T-Bar drive

5mm A/F Allen Key

4mmA/F Allen Key - 2 off

Support the bike by clamping the seat post in a work stand. Remove the rear wheel. Us-

ing the 5mm Allen key to hold the Socket head cap screw (15) and the 10mm A/F socket

to loosen nut (13), remove nut (13) and washer (14) then remove the bolt (15) and

washer (14) from the other side of the bike. The shock unit should now be disconnected

from the swing arm. Next, in order to remove the shock unit from the main frame (1)

use the two 4mm Allen keys to loosen the screws (2). Whichever screw loosens first,

remove the shaft (5) from the opposite side. The shock unit may now be removed from

the bike. Ensure you collect the top hat bushes (6) from the shock mount (1) as you

remove the shock.

Marin FRS Quad-Link Service Manual

Page 3 2004 Edition 1

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AUTOHRIZED BRAND LOGOS : 2/1/09

MARIN BIKES : CORPORATE BRAND LOGOTYPE

MARIN BIKES : BOLD STROKE LOGOTYPE & BEAR HEAD ICON

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LOGOS MAY NOTBE ALTERED IN ANY WAY. If you have any questions or special considerations please contact

AUTOHRIZED BRAND LOGOS : 2/1/09

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Page 2 Page 3

Marin FRS Quad-Link Service Manual

3.0: Figure 2, Exploded Diagram Rear Suspension Assembly

Page 4 2004 Edition 1

Marin FRS Quad-Link Service Manual

It is vital the Link Spacer Tool (8) is placed here to prevent bending of the One

Piece Link during installation of the Bearings. Apply Loctite 641 on the outside of the

KP5AX bearing (2) and on the inside bearing surface of the Link (1). Using the Bearing

insertion Tool (9), assemble as shown in figure 5 using an engineers vice with ‘soft jaws’ to

prevent any damage to the Link. Align the components and press the bearing into the link.

Ensure the bearing presses in squarely, and is correctly seated in the bottom of it’s hous-

ing. Repeat until three KP5AX bearing are installed. The final bearing will require the Cen-

ter Spacer to be fitted at the same time as pressing the bearing in.

8.3 Figure 6: Diagram of KP5AX Bearing and Centre Spacer Installation

8.4: Parts List. Centre Spacer and KP5AX Bearing Installation into 1 Piece Link.

No. Description Qty.

1 35mm/1 Piece Link 2

2 KP5AX Bearing 4

3 Centre Spacer 1

8 Link Spacer Tool 1

9 Bearing Insertion Tool 1

8.5 Installation of KP5AX Bearing and Centre Spacer

The final bearing will require the Center Spacer (3) to be fitted at the same time as press-

ing the bearing in. Place the Link Spacer Tool (8) in between the One Piece Link (1) as

shown in Figure 6. It is vital the Link Spacer Tool (8) is placed here to prevent

bending of the One Piece Link during installation of the Bearing.

Page 9 2004 Edition 1

7.1: Extraction of KP5AX Bearings from 1 Piece Link Assembly: Figs 3,4a,4b,4c,4d

Remove all the outer shield washers (4,5,6) and wipe off old grease from the Labyrinth

areas. Assemble the link as shown in Fig 4a on top of the jaws of an engineer’s vice, sup-

porting the link whilst allowing the KP5AX bearing to be drifted out between the vice jaws.

Slide the M8x65mm bolt (7) through the top KP5AX bearing, and drift out the Centre

Spacer (3) and KP5AX bearing (2) together as shown in figure 4b. Once the Centre Spacer

(3) has been removed from the assembly, the remaining KP5AX bearings can be removed.

To remove the remaining 3 KP5AX bearings (2) from the one piece link body (1) assemble

the components as illustrated in Figure 4c. Using an inner top hat washer (4) seated in the

bearing, slide the M8x65mm bolt (7) through the top KP5AX bearing, and repeat the pro-

cedure to drift out the lower KP5AX bearing. Once these bearings have been removed, it

should be possible to remove the remaining two KP5AX bearings with a normal size drift

tool.

8.0: Figure 5: Diagram of KP5AX Bearing Installation

8.1: Part List. KP5AX Bearing Installation into 1 Piece Link.

No. Description Qty.

1 35mm 1 Piece Link 2

2 KP5AX Bearing 4

3 Centre Spacer 1

8 Link Spacer Tool 1

9 Bearing Insertion Tool 1

8.2: Installation of KP5AX Bearings into One Piece Link

To install the KP5AX (2) bearings into the links, first ensure all bearing surfaces and faces

are free from grease old retaining compound and all other contamination. Slide the Link

spacer tool (8) in between the inner faces of the One Piece Link (1), as shown in Figure 5.

Marin FRS Quad-Link Service Manual

Page 8 2004 Edition 1

3.1: Part List, Rear Suspension Assembly: Figure 2

No. Description Part Code Qty

1. Swing Arm 1

2. Main Frame 1

3. Link Assembly 2

4. M6 Cap Head Bolt BOLTM6x70-4B 2

5. Nyloc nut M6 Nyloc 5

6. M6 Cap Head Bolt BOLTM6x85-4B 2

7. Washer M6 Washer 6

8. Screw socket head cap BOLTM6x55-4B 1

9. Top hat bush TOPHAT2012 2

10. Shaft CRO3036 1

11. Collar 97-3035 2

12. Washer M5 Washer 2

13. Screw socket head cap M5 x 16 2

14. Plastic Plug 97-3032 4

Not Pictured: Fox shock Air Vanilla Float R 35.5/22 1

4.0: Removal of Swinging Arm. Figure 2

Tools required: 4mm A/F & 5mm A/F Allen keys

To remove the swinging arm from the bike, follow the procedure to remove the shock unit

(Section 2.0). Next remove the rear disc brake calliper from the drop-out, and detach hose

from the stops. Do not allow calliper to dangle unsupported by it’s hose. Remove rear de-

railleur mechanism from the swing arm (1). Next remove the two Plastic Plugs (14). Now

using the 5mm Allen key to hold the bolt (6) at the front of the swing arm (1) and using

the 10mm A/F socket loosen and remove the nut (5) and washer (7), now remove the bolt

(6) and washer (7). The swing arm (1) should now be released form the front link. Next

use the 5mm Allen key to hold the bolt (6), in the swing arm (1) just behind the seat tube,

use the 10mm A/F socket loosen and remove the nut (5) and washer (7), now remove the

bolt (6) and washer (7). It should now be possible to remove the Swinging arm (1) by lift-

ing it vertically upwards then forwards away from the main frame (2).

5.0: Removal of Links. Figure 2

Tools Required: 10mmA/F socket with ratchet or T-Bar drive

5mm A/F Allen Key

The two link assembly’s (3) used on the MARIN QUAD FRS are identical, as are the removal

procedures. Having followed the procedures above to remove the shock unit and swinging

arm (1), use the 5mm Allen key to hold the bolt (4) then use the 10mm A/F socket to

loosen and remove the nut (5), next remove the bolt (4), now remove the link assembly

(3) from the main frame(2), taking care not to drop the washers.

Marin FRS Quad-Link Service Manual

Page 5 2004 Edition 1

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LOGOS MAY NOTBE ALTERED IN ANY WAY. If you have any questions or special considerations please contact

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Page 4 Page 5

Marin FRS Quad-Link Service Manual

6.0: Figure 3, Exploded Diagram 1 Piece Link Assembly

Page 6 2004 Edition 1

6.1: Parts List: 1 Piece Link Assembly. Figure 3

No. Description Part Code Qty

1. 1 Piece Link body 1

2. KP5AX Bearing KP5A 4

3. CentreSpacer Spacer4B 1

4. Shield washer Washin4B 2

5. Shield washer Washpl4B 2

6. Shield washer Washout4B 2

7.0: Figures 4a,4b,4c,4d, Illustration of Bearing Removal

Marin FRS Quad-Link Service Manual

Page 7 2004 Edition 1

Figure 4a: Figure 4b:

Figure 4c Figure 4d

Marin FRS Quad-Link Service Manual

6.0: Figure 3, Exploded Diagram 1 Piece Link Assembly

Page 6 2004 Edition 1

6.1: Parts List: 1 Piece Link Assembly. Figure 3

No. Description Part Code Qty

1. 1 Piece Link body 1

2. KP5AX Bearing KP5A 4

3. CentreSpacer Spacer4B 1

4. Shield washer Washin4B 2

5. Shield washer Washpl4B 2

6. Shield washer Washout4B 2

7.0: Figures 4a,4b,4c,4d, Illustration of Bearing Removal

Marin FRS Quad-Link Service Manual

Page 7 2004 Edition 1

Figure 4a: Figure 4b:

Figure 4c Figure 4d

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LOGOS MAY NOTBE ALTERED IN ANY WAY. If you have any questions or special considerations please contact

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LOGOS MAY NOTBE ALTERED IN ANY WAY. If you have any questions or special considerations please contact

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