Marzocchi Bomber User manual

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I. USE OF THIS MANUAL
GENERAL WARNINGS
WARNING!
Failure to follow the warnings and
instructions could result in failure of the
product, an accident, personal injury or
death.
• Carefully read, understand and follow the
instructions given in this manual. It is an
essential part of the product. Keep it in a safe
place for future reference 1.
• Please be advised that suspension system
installation, service and repair tasks require
specialized knowledge, tools and experience.
General mechanical aptitude may not be
sufficient to properly install, service or repair
your suspension system. If you have any
doubt whatsoever regarding your ability to
properly service or repair your suspension
system, please have your suspension system
installed and/or serviced by an authorized
Marzocchi Service Center. Improper
installation, service or repair can result in an
accident, resulting in personal injury or death.
• Failure to follow warnings and instructions
provided in this manual could result in failure
of the product, resulting in an accident,
personal injury or death.
• Please note that throughout this manual,
reference is made that “an accident” could
occur. Any accident could result in loss of
bicycle control, damage to your bicycle or its
components, and more importantly, cause you
or a bystander to sustain severe personal
injury or death.
• This manual does not explain how to
assemble or disassemble the fork from the
bicycle, the wheel, the steering set, or any
other component directly or indirectly
associated with the fork that is not actual a
part of the fork.
WARNING!
Descriptions preceded by this symbol
contain information, instructions, or
procedures, which, if not followed, can result
in damage or malfunction of the fork,
damage to the environment, an accident,
personal injury or death.
REMEMBER
Descriptions preceded by this symbol contain
information, or procedures recommended by
MARZOCCHI for optimum use of the fork.
• If you have any questions regarding the care,
maintenance or use of your suspension
system, please contact your nearest
Marzocchi service center directly. A list of
service centers can be found at the end of this
manual or on the Internet at
www.marzocchi.com.
• The user of this Marzocchi product expressly
recognizes and agrees that there are risks
inherent in motorcycle riding, including but not
limited to the risk that a component of your
suspension system can fail, resulting in an
accident, personal injury or death. By his/her
purchase and use of this Marzocchi product,
the user expressly, voluntarily and knowingly
accepts and assumes these risks, including
but not limited to the risk of passive or active
negligence of Marzocchi or hidden, latent or
obvious defects in the product, and agrees to
hold Marzocchi, its distributors and retailers
harmless to the fullest extent permitted by law
against any resulting damages.
1Marzocchi reserves the right, in its sole
discretion, to make changes to the product at
any time and without prior notice.
A.
GENERAL SAFETY RECOMMENDATIONS
Marzocchi Suspension Systems are designed
for different riding styles. Some are designed to
only absorb the shocks of an uneven road
surface in order to give the rider more control
over his bicycle. Others are designed for other
purposes. You must select and use the correct
suspension system for your style of riding. Read
and follow the “Intended Use Instructions” in this

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manual. Failure to select and properly use the
correct fork could result in an accident, personal
injury or death.
Please note that there are inherent risks
associated with downhill, freeride, cross-
country, marathon, trekking, dirt jumping, and
urban style riding. Severe injury or death could
result from these riding styles. Learn how to
ride, never ride beyond your capabilities, be
sure to use the proper safety equipment, and be
sure that all your riding equipment is in excellent
condition.
The lifespan of Marzocchi products depends on
many factors, such as riding style and riding
conditions. Impacts, falls, improper use, or
harsh use in general, may compromise the
structural integrity of the suspension system
and significantly reduce its lifespan. The
suspension system is also subject to wear over
time. Please have your bicycle regularly
inspected by a qualified mechanic for any oil
leaks, cracks, chips, deformation, or other signs
of fatigue (use of penetrating fluid or other visual
enhancers to locate cracks is recommended). If
the inspection reveals any deformation, cracks,
impact marks, stress marks or bent parts, no
matter how slight, immediately replace the
component; components that have experienced
excessive wear also need immediate
replacement. The frequency of inspection
depends on many factors; check with your
Authorized Marzocchi Representative to select
a schedule that is best for you. If you weigh 82
kg/180 lbs or more, you must be especially
vigilant and have your bicycle inspected more
frequently (than someone weighing less than 82
kg/180 lbs.) for any evidence of cracks, leaks,
deformation, or other signs of fatigue or stress.
Check with your mechanic to discuss whether
your forks are suitable for your use, and to
determine the frequency of inspections.
Be sure that the periodic maintenance schedule
is strictly followed.
Please be advised that if the maintenance and
repair procedures provided in this manual are
not properly performed, or the other instructions
in this manual are not followed, an accident
could occur.
The symbol calls attention to the tasks
which must be performed with extreme care to
avoid an accident.
Never make any modifications whatsoever to
any component of the suspension system.
The components of Marzocchi’s suspension
system are designed as a single integrated
system. To avoid compromises in terms of
safety, performance, durability and function, and
to prevent voiding of the warranty, do not
substitute Marzocchi components with
components manufactured by other companies.
Parts that have been bent or otherwise
damaged in an accident, or as a result of any
other impact, must not be re-straightened. They
must be replaced immediately with original
Marzocchi parts.
When using a bicycle carrier (automobile roof
rack or rear-hitch mount), be sure to fully loosen
the quick release fastener on the carrier when
mounting or removing your bicycle. Additionally,
be sure to always keep your bicycle in a vertical
position when mounting or removing your
bicycle to and from the bicycle carrier. Failure to
fully loosen the quick release fastener, or any
bending action while mounting or removing your
bicycle to and from the carrier, could result in
scratching, bending, or otherwise damaging
your suspension system.
Damage to your forks can occur if your bicycle
strikes, at any speed, any overhead object, such
as a parking garage, bridge, tree limb or other
abutment, while attached to a bicycle carrier. In
the event of such occurrence, have your forks
inspected by an authorized Marzocchi Service
Center before you ride.
Never spray your bicycle with water under
pressure. Pressurized water, even from the
nozzle of a small garden hose, can pass under
seals and enter your Marzocchi forks, thereby
affecting its operation. Wash your bicycle and
Marzocchi forks by wiping them down with water
and neutral soap.

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Always wear a properly fitted and fastened
bicycle helmet, that has been approved by ANSI
, SNELL or CE, and any other safety equipment
necessary for your riding style.
When riding in wet conditions, remember that
the stopping power of your brakes is greatly
reduced and that the adherence of the tires on
the ground is considerably reduced. This makes
it harder to control and stop your bicycle. Extra
care is required when riding your bicycle in wet
conditions to avoid an accident.
Avoid biking at night because it is more difficult
for you to be seen by traffic, and it is more
difficult for you to see obstructions on the
ground. If you do ride at night, you should equip
your bicycle with and use a headlight and a
taillight.
Wear clothes that are snug-fitting and that make
you visible to traffic, such as neon, fluorescent,
or other bright colors.
B. BEFORE EVERY RIDE
DO NOT RIDE YOUR BICYCLE IF IT DOES
NOT PASS THIS PRE-RIDE TEST. CORRECT
ANY CONDITION BEFORE YOU RIDE.
Check your forks for any leaks or other evidence
of oil, which is indicative of a problem with your
forks. Be sure to turn your bicycle upside down
to check areas such as the underside of the
crown for evidence of an oil leak.
Be sure that all components of you forks, and
the remainder of your bicycle, including, but not
limited to, your brakes, pedals, handgrips,
handlebars, frame, and seating system, are in
optimum condition and suitable for use.
Be sure that none of the components of your
suspension system, or the remainder of your
bicycle, are bent, deformed, cracked, chipped,
out of aliment, or otherwise damaged.
Check to be sure that all quick release
fasteners, nuts and bolts are properly adjusted.
Bounce the bicycle on the ground while listening
and looking for anything that may be lose.
Be sure that your wheels are perfectly centered.
Spin the wheels to be sure that they do not
wobble up and down or from side to side, and
that they do not make contact with the fork legs
or brake pads while rotating.
Be sure that all cables and other components of
your braking system are in their proper position,
properly adjusted and that your braking system
is functioning properly.
Be sure that your tires are inflated to the correct
pressure and that there is no damage
whatsoever in the tread or sidewall of the tire.
Check all reflectors to make sure that they are
clean, straight, and securely mounted.
Be sure to read and follow all the instructions
and warnings that originally accompanied your
bicycle.
Learn and follow the local bicycle laws and
regulations, and obey all traffic signals, signs
and laws while you ride.
II. INTENDED USE INSTRUCTIONS
A. SELECT THE CORRECT FORK FOR
YOUR RIDING STYLE
Marzocchi suspension forks are among the
most durable and technologically advanced
forks on the market today. However, no fork can
withstand misuse, abuse or improper use that,
over a short period of time, can cause your forks
to fail when you least expect it.
It is critical that you select and use the fork that
is appropriate for your riding style, and that you
use the fork properly.
WARNING!
Failure to properly match the forks to your
frame could cause the forks to fail, resulting
in a loss of control of the bicycle, and
possible serious injury or death to the rider.
In addition, improperly matching your forks
to your frame will void the forks’ warranty.

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1. Identify Your Riding Style:
Cross Country (“XC”)/Marathon: Riding along
hilly trails where some bumps and smaller
obstacles, such as rocks, roots, or depressions,
may be encountered. XC riding does not include
jumps or ”drops” (riding off rocks, fallen trees or
ledges) from any height. XC forks must be used
with tires specifically designed for cross country
riding, and disk, rim or linear pull brakes.
All Mountain (“AM”):Riding with more
emphasis on aggressive XC riding over and
around larger obstacles. This riding style does
not include jumps. These forks should only be
used with disk brakes, and those frames,
wheels and other components specifically
designed for this riding style. The disk brakes
must be attached to the designated mounting
points provided on the fork. Never make any
modification to your fork when attaching any
equipment.
Trekking: Trekking is similar to XC riding, but
less aggressive. It involves riding at a slower
pace and not riding over obstacles such as
rocks, roots, and depressions. You should only
attach generators and racks to the designated
mounting points provided on the forks. Never
make any modification to your fork when
attaching any equipment.
FreeRide (“FR”): This riding style is for skilled
riders, and involves steep, aggressive slopes,
large obstacles, and moderate jumps. Freeride
forks should be used only with disk brakes, and
those frames, wheels and other components
specifically designed for this riding style. The
disk brakes must be attached to the designated
mounting points provided on the fork. Never
make any modification to your fork when
attaching any equipment.
Dirt Jumper (“DJ”) /Urban Riding: This “BMX”
or ”motocross” style of riding is only for the most
skilled riders, and involves jumping from one
mound of dirt to another. It also includes riding
over and around ”urban obstacles” such as
man-made, or other concrete, structures. These
forks should only be used with disk brakes, and
those frames, wheels and other components
specifically designed for this riding style. The
disk brakes must be attached to the designated
mounting points provided on the fork. Never
make any modification to your fork when
attaching any equipment.
Downhill (“DH”) /Extreme Freeride: This
discipline is only for professional or highly skilled
riders. It includes relatively high jumps or “drops’
and negotiating larger obstacles such as
boulders, fallen trees, or holes. These forks
should be used only with disk brakes, and those
frames, wheels and other components
specifically designed for this riding style. The
disk brakes must be attached to the designated
mounting points provided on the fork. Never
make any modification to your fork when
attaching other equipment.
WARNING!
Ride ONLY in areas specifically designated
for your riding style.
2. Select the Correct Fork for Your Riding
Style from the Table below.
Using the table below, select the fork that
matches your riding style. Please see your
Marzocchi retailer, or contact Marzocchi directly,
if you require assistance in selecting the correct
fork.

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Tab 1: 2006 Fork Riding Categories and Intended USE
Trekking XC /
Marathon
All
Mountain
Urban Riding
Dirt Jumping Freeriding
Extreme
Freeriding
Downhill
Downhill
TXC Marathon
RACE All Mountain SL Dirt Jumper 1 Z1 SL Doppio Air 66 SL Junior T
TXC
ECC
Marathon SL
Doppio Air All Mountain 1 Dirt Jumper 2 Z1 Light 66 RC2X 888 RC2X
Marathon XC All Mountain 1
ETA Dirt Jumper 3 Z1 Sport 66 Light 888 RC2
MX Pro Race All Mountain 2 Dirt Jam Pro Drop-Off I 66 VF 888 VF2
MX Pro SL All Mountain 3 Dirt Jam
Comp Drop-Off II 66 VF2 888 VF
MX Pro AM 1 / TW D-Street 24” Drop-Off III 66 VF2 LT Monster
MX Comp AM 2 / TW Drop-Off IV 888 RC2X Drop-Off
Triple
MZ I AM 3 / TW 888 RC2 Super T
MZ II AM 4 / TW 888 VF2
MZ III 888 VF
Gran Fondo
RC
Gran Fondo 1
Gran Fondo 2
Gran Fondo 3
USE ONLY FOR:
FOR MORE DETAILS SEE
OWNERS MANUAL OR
WWW.MARZOCCHI.COM
• CROSS COUNTRY
• ALL MOUNTAIN
• FREERIDE
• DIRT JUMPER
• FREERIDE EXTREME
• DOWNHILL
WARNING
DO NOT USE FOR:
Improper use of this fork
can result in fork failure
and personal injury
DO NOT USE FOR:
USE ONLY FOR:
FOR MORE DETAILS SEE
OWNERS MANUAL OR
WWW.MARZOCCHI.COM
• CROSS COUNTRY
• ALL MOUNTAIN
• FREERIDE
• DIRT JUMPER
• FREERIDE EXTREME
• DOWNHILL
WARNING
Improper use of this fork
can result in fork failure
and personal injury

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3. Ride Properly – Do Not Misuse or Abuse
of Your Forks
Never abuse or misuse your forks. Learn how to
ride, and always ride within your abilities. An
out-of-control ride puts the equivalent of years
of hard use on your forks after only a few rides.
Learn how to properly flow around obstacles on
the trail. Hitting obstacles such as rocks, trees
or holes straight-on puts forces on your fork it
was not designed to absorb.
Landing improperly after a jump or drop also
puts forces on your fork it was not designed to
absorb. You should only perform jumps or drops
when a transition, or down ramp, is available to
help your bicycle absorb the impact forces
generated during the landing by having both
wheels smoothly make contact with the
transition, or down ramp, at the same time. Any
other type of landing is dangerous, as it could
result in a component part failure and an
accident. The steepness and length of the
transition, or down ramp depends on the height
from which you jump or drop. Every situation is
different for every rider, so consult with an
experienced rider before attempting any jump or
drop.
WARNING!
Failure to properly flow around obstacles on
the trail, or failure to properly land after a
jump or drop, could cause your forks to fail,
resulting in a loss of bicycle control, serious
injury, or death to the rider.
WARNING!
Your forks require regular maintenance and
repair. The harder you ride, the more often
you must inspect and perform maintenance
on your forks. If your forks are leaking, bent,
deformed, cracked, or chipped, no matter
how slight, immediately have a Certified
Marzocchi Repair Center inspect the forks
before you ride again.
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”

MZ034
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English

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1 Introduction .................................... 122
1.1 Conventions .................................. 122
1.1.1 Orientation of the Fork .............. 122
2 Technical information .................... 123
2.1 Spring System ............................... 123
2.2 Damping System ........................... 124
2.3 Lubrication and Cooling ................. 126
2.4 Sliding Bushing and Oil Seals ....... 126
3 Installation ...................................... 127
3.1 Installing on the Frame .................. 127
3.2 Installing the Brake System ........... 128
3.3 Wheel Installation .......................... 129
3.4 Wheel Axle Securing System ........ 129
3.4.1 Wheel Installation On A
Standard Fork ........................... 129
3.4.2 Wheel Installation On ø 32 mm
Forks With A ø 20 mm
Through-Hole Axle ................... 130
3.4.3 Wheel Installation On 66
And 888 Series Forks ............... 131
3.4.4 Wheel Installation On
Monster Series Forks ............... 132
3.5 Fender Installation ......................... 133
3.6 Handlebar Clamp Installation ........ 133
3.6.1 Handlebar Clamp Installing
On All Dual Crown Models
(except the 888 Series) ............ 133
3.6.2 Handlebar Clamp Installation
For The 888 Series ................... 134
4 Maintenance ................................... 135
4.1 Problems - Diagnosis - Solutions .. 135
4.2 Periodic Maintenance .................... 136
4.3 General Maintenance
Recommendations ........................ 137
4.4 Cleaning The Fork Legs ................ 138
4.5 Monster Air-Bleeding .................... 138
5 Adjustments ................................... 139
5.1 Adjustment Kit And Springs ........... 139
5.2 Spring Preload ............................... 139
5.3 Positive Air .................................... 139
5.4 SAG ...............................................140
5.5 Negative Air ...................................141
5.6 PAR - Air Progression
At Travel End .................................141
5.7 Rebound Adjustment .....................141
5.8 Compression Adjustment ...............141
5.9 ETA (Extension Travel Adjustment) 141
5.10 TAS (Travel Adjustment System) ...142
5.11 TST (Terrain Selection Technology) 142
5.12 TST cartridge with remote control ..142
5.13 RC2 ................................................143
5.14 RC2X .............................................143
6 Summarizing tables ........................146
7 Warranty ..........................................167
7.1 Warranty for EU
countries ........................................167
7.2 Warranty rest of the world
– USA included ..............................168

Introduction
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1 INTRODUCTION
1.1 Conventions
1.1.1 Orientation of the Fork
Picture 1 - Conventional orientation of the fork
TOP
BOTTOM
BACKFRONT
LEFT
RIGHT
1

Technical information
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2 TECHNICAL INFORMATION
2.1 Spring System
Inside MARZOCCHI forks you will find coil
springs, or air, used as suspension mechanism.
Table 1 - Spring Systems
Fork Spring system
Right fork leg Left fork leg
Marathon Race Air Air
Marathon SL Doppio Air Air Air
Marathon XC Air Coil spring
MX Pro Race Air Air
MX Pro SL Air Air
MX Pro Air Air
MX Pro + ETA Air Coil spring
MX Pro + TAS Air Coil spring
MX Comp Air Air
MX Comp + ETA Air Coil spring
MX Comp + TAS Air Coil spring
All Mountain SL Air Air
All Mountain I Air Coil spring
All Mountain I ETA Air Coil spring
All Mountain II Air Air
All Mountain II + ETA Air Coil spring
All Mountain II + TAS Air Coil spring
All Mountain III Air Air
Z1 SL Doppio Air Air Air
Z1 Light Air Coil spring
Z1 Light + ETA Air Coil spring
Z1 Sport Coil spring Coil spring
Z1 Sport + ETA Coil spring Coil spring
66 SL Air Air
66 RC2X Coil spring Coil spring
66 Light Air Coil spring
66 Light + ETA Air Coil spring
66 VF Coil spring Coil spring
66 VF2 Coil spring Coil spring
66 VF2 + ETA Coil spring Coil spring
66VF2LT Coil spring Coil spring
Dirt Jumper 1 Coil spring Coil spring
Dirt Jumper 2 Coil spring Coil spring
Dirt Jumper 3 Coil spring Coil spring
D-Street 24” Coil spring Coil spring
888 RC2X Coil spring Coil spring
888 RC2 Coil spring Coil spring
888 VF2 Coil spring Coil spring
888 VF Coil spring Coil spring
Monster Coil spring Coil spring
Junior T Coil spring Coil spring
2

Technical information
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2.2 Damping System
The damping load that is generated during
compression and rebound of the fork legs can
be adjusted by hydraulic valve pumping rods, or
by special cartridges.
Table 2 - Damping Systems
Fork Damping Systems
Right fork leg Left fork leg
Marathon Race TST cartridge (with optional remote control) DOPPIO AIR cartridge
Marathon SL Doppio
Air TST cartridge (with optional remote control) DOPPIO AIR cartridge
Marathon XC TST cartridge (with optional remote control) TAS cartridge
MX Pro Race SSVF pumping rod with rebound setting by
external adjuster /
MX Pro SL TST cartridge (with optional remote control) /
MX Pro SSVF pumping rod with rebound setting by
external adjuster /
MX Pro + ETA SSVF pumping rod with rebound setting by
external adjuster ETA cartridge
MX Comp SSV pumping rod with rebound setting by
internal adjuster /
MX Comp + ETA SSV pumping rod with rebound setting by
internal adjuster ETA cartridge
All Mountain SL TST cartridge (with optional remote control) Cartuccia DOPPIO AIR
All Mountain I TST cartridge (with optional remote control) TAS cartridge
All Mountain I ETA TST cartridge (with optional remote control) ETA cartridge
All Mountain II VF2 pumping rod with rebound setting by
external adjuster
Pumping rod with
compression setting by
external adjuster
All Mountain II + ETA VF2 pumping rod with rebound setting by
external adjuster ETA cartridge
All Mountain II + TAS VF2 pumping rod with rebound setting by
external adjuster ETA cartridge
All Mountain III VF2 pumping rod with rebound setting by
external adjuster /
Z1 SL Doppio Air RC2 cartridge with rebound and compression
setting by external adjuster DOPPIO AIR cartridge
Z1 Light RC2 cartridge with rebound and compression
setting by external adjuster /
Z1 Light + ETA RC2 cartridge with rebound and compression
setting by external adjuster ETA cartridge
Z1 Sport VF2 pumping rod with rebound setting by
external adjuster
Pumping rod with
compression setting by
external adjuster
Z1 Sport + ETA VF2 pumping rod with rebound setting by
external adjuster Cartuccia ETA
66 SL RC2 cartridge with rebound and compression
setting by external adjuster Cartuccia DOPPIO AIR
66 RC2X RC2 cartridge with rebound and compression
setting by external adjuster
X cartridge with
compression setting by
external adjuster at travel
end
66 Light RC2 cartridge with rebound and compression
setting by external adjuster /
66 Light + ETA RC2 cartridge with rebound and compression
setting by external adjuster ETA cartridge

Technical information
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SSV: The SSV system, thanks to the speed
sensitive valve, allows for control of the
damping system based on the fork’s
compression and rebound speed, as well as the
fork’s position in the travel. SSV pumping rods
can have a fixed or adjustable rebound setting
by internal or external adjusters.
SSVF: The SSVF system is the evolution of the
SSV system to further improve the fork’s
sensitivity, thanks to the spring-preloaded valve.
SSVF pumping rods can have a fixed or
adjustable rebound setting by internal or
external adjusters.
VF2: In the new VF2 system the SSV system
has evolved to further improve the damping
control based on the fork’s rebound speed, as
well as the fork’s position in the travel. VF2
pumping rods have an adjustable rebound
setting by internal or external adjusters.
66 VF SSVF pumping rod with rebound setting by
internal adjuster /
66 VF2 SSVF pumping rod with external rebound
adjustment
Pumping rod with
compression setting by
external adjuster
66 VF2 + ETA SSVF pumping rod with external rebound
adjustment ETA cartridge
66VF2LT SSVF pumping rod with external rebound
adjustment
Pumping rod with
compression setting by
external adjuster
Dirt Jumper 1 VF2 pumping rod with rebound setting by
external adjuster
Pumping rod with
compression setting by
external adjuster
Dirt Jumper 2 VF2 pumping rod with rebound setting by
external adjuster /
Dirt Jumper 3 VF2 pumping rod with rebound setting by
internal adjuster /
D-Street 24” Not adjustable SSV damping rod Not adjustable SSV
damping rod
888 RC2X RC2 cartridge with rebound and compression
setting by external adjuster
X cartridge with
compression setting by
external adjuster at travel
end
888 RC2 RC2 cartridge with rebound and compression
setting by external adjuster /
888 VF2 SSVF pumping rod with rebound setting by
external adjuster
Pumping rod with
compression setting by
external adjuster
888 VF SSVF pumping rod with rebound setting by
internal adjuster /
Monster HSCV cartridge with rebound and compression
setting by external adjuster
HSCV cartridge with
compression setting by
external adjuster at travel
end
Junior T SSV pumping rod SSV pumping rod
HSCV: The HSCV system allows for more
controlled damping by enabling the fork’s
sensitivity to be adjusted according to trail type,
and allowing for adjustment of the fork’s
resistance to bottoming. The HSCV system can
absorb harsh impacts, helping you maintain
control of your mountain bike.
The HSCV cartridges may be provided with
external rebound, or compression, adjustments.
ETA: The ETA system allows for adjustments to
be made to the extension travel and fork’s
locking, while still offering 25-30mm of travel.
TAS: The TAS system not only offers the
extension travel adjustment, like the ETA
system, but also permits the modification of the
total travel - allowing the fork’s maximum length
to be increased by 20 mm.

Technical information
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TST: The TST system uses a sealed cartridge
with a rubber lung for oil collection. The TST
cartridge is provided with a rebound adjuster in
the lower area and a 5-position compression
adjuster in the upper area.
Remote control for TST cartridge: On request,
the TST cartridge can be supplied with a remote
control that lets the riders lock the fork keeping
their hands on the handlebar.
DOPPIO AIR: The DOPPIO AIR system is
provided with three independent air chambers,
allowing customization of settings according to
the rider’s needs.
RC2: This new system allows for control of the
rebound and compression damping by means of
two external adjusters, as well as of the spring
preload.
RC2X: This system is the evolution of RC2
system with an extra X-cartridge on the left leg
for the control of the fork’s compression at travel
end.
2.3 Lubrication and Cooling
Pumping rods are immersed in oil (Open Bath
System). This system provides proper lubrication
and cooling of the inner sliding parts.
Furthermore, the oil volume works as a damping
and setting element.
The Open Bath system reduces the
maintenance frequency compared to a sealed
cartridge system. On models of the fork that use
elastomers, the proper internal lubricant is
grease.
2.4 Sliding Bushing and Oil Seals
Stanchion tubes are guided in the sliders by two
Teflon‘-coated bushings, free from static friction.
The seal system minimizes oil leaks, and
contamination from particles entering the fork, by
means of a special, dual-lip oil seal and a dust
seal at the top of each slider

Installation
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3 INSTALLATION
3.1 Installing on the Frame
The fork is supplied with an “A-Head Set” steer
tube to be cut according to the frame size the
fork is being installed on.
Installing the fork on the bicycle frame is a
delicate and critical operation, and should only
be performed by skilled, trained personnel.
WARNING!
Suspension system installation requires
specialized knowledge, tools and
experience. General mechanical aptitude
may not be sufficient to properly install your
suspension system. Please have your
suspension system installed only by an
authorized 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.
Replacement of the steer tube requires the use
of specialized tools, so it should only be
performed at one of our authorized service
centers.
WARNING!
On all dual crown MY 2006 BOMBER models
the lower crown is clamped to the
stanchions using bolts. In this case, please
be aware of the following precautions during
installation:
• In case of oversized diameter areas on the
stanchions, the crowns clamping can only be
done in the shaded area shown in Picture
2A.
• In case of reference notches on the
stanchions, the lower part of the lower crown
must be positioned over the notch.
• On the Monster forks, the distance between
the lower part of the lower crown and the dust
seal, when the fork is at travel end, must be at
least 4 mm.
• On the dual crown forks the maximum length
of the steer tube between the two crowns (see
Picture 2B) must be smaller than the values
(H) shown in Table 3.
Picture 2 - Dual crown forks installation on the frame:
(2A) Crowns fastening, (2B) Steer tube
maximum length between crowns
Table 3 - Steer tube maximum length between crowns
Model Maximum length
between crowns (H)
Monster 190 mm
888 158 mm
A
B
H
3

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3.2 Installing the Brake System
Installing the brake system is a delicate and
critical operation that must be carried out by
specialized personnel.
WARNING!
Brake system installation requires
specialized knowledge, tools and
experience. General mechanical aptitude
may not be sufficient to properly install your
brake system. Please have your brake
system installed only by an authorized
Marzocchi Service Center.
Improper installation of a disk brake system
can overstress the caliper mountings, which
may cause the caliper mountings to break,
resulting in loss of control of the bicycle, an
accident, personal injury, or death.
Be sure that the brake system installation is
also performed in strict compliance with the
instructions provided by the brake system
manufacturer.
Use only brake systems that comply with the
forks specifications, taking into consideration the
contents of the summarizing tables contained in
this manual..
Table 4 - Brake system settings
Picture 3 - Braking system settings
Fork Max disk dimension and fastening system V-Brake setting
Marathon Post Mount 6”
Removable setting
MX
D-Street 24”
XC INTL STD 8”
(Installation of 8" disk is only possible when the specific
adapter is supplied by the brake system manufacturer)
All Mountain Post Mount 6"
(Installation of 8" disk is only possible when the specific
adapter is supplied by the brake system manufacturer)
No
66
Z1 XC INTL STD 6”
(Installation of 8" disk is only possible when the specific
adapter is supplied by the brake system manufacturer)
Dirt Jumper
888
Junior T
Monster Post Mount 8”
All Mountain
66
Z1
Dirt Jumper
888
Junior T
Brake disk system sheath
supports setting
V-Brake system
removable setting
Marathon
MX

Brake disk system sheath
supports setting
D- Street 24"
D- Street 24"
B
C
A

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WARNING!
A special thread-lock treatment is applied to
the thread on the bolts (see 3A in Picture 3).
Bolts that are installed and later removed
lose this thread-lock treatment, and
therefore can never be used again.
WARNING!
Before installing a Post Mount braking
system, check that the protection film has
been removed from the brake caliper.
WARNING!
Make sure, before every ride, that the brake
cable of the disk brake system is correctly
connected to the proper mounting (see 3B &
3C in Picture 3).
WARNING!
The brake cable must never touch the crown and
stanchions.
3.3 Wheel Installation
Table 5 - Maximum wheel dimension
Fork
Maximum
wheel
dimension
Marathon 2.2” x 26”
MX - All Mountain - Z1 - 66 -
Dirt Jumper - 888 - Junior T 2.8” x 26”
Monster 3.0” x 26”
D-Street 24” 2.5” x 24”
In the event you need to install wheels with
dimensions larger than those specified in Table
5, above, you must verify that:
• The tire turns freely;
• The tire does not make any contact with the
brake arch or V-Brake system;
• The distance between the inflated tire and the
lower part of the lower crown is at least four
(4) mm when the forks’ legs are fully
compressed
Picture 4 - Wheel securing systems: (4A) standard dropouts, (4B)ø20mm through-hole axle (forks with ø32mm
stanchions), (4C)ø20mm through-hole axle (66 and 888 series forks), (4D) ø 20mm through-hole axle
(Monster).
ABC D
3.4 Wheel Axle Securing System
The system for securing the wheel axle to the
fork sliders can be standard, which uses the
traditional advanced dropouts, or have a 20 mm
diameter through-hole axle - see Picture 4
below.
Forks that are created for more intensive use
are provided with a wheel fastening system,
which originates from the motocross application
and uses a 20 mm axle.
3.4.1 Wheel Installation on a Standard
Fork
Install the wheel in compliance with the wheel
manufacturer’s instructions. For correct fork
function after installing the wheel, you will need
to:
• Check the fork-wheel alignment by fully
compressing the fork a few times. The wheel
should not make contact with, or come close
to any portion of the fork.
• Lift the front of the bicycle, and spin the wheel
a few times to verify correct alignment and
spacing with the disk brake or the V-Brake
brake pads. Check the owner’s manual of the
brake system for the proper specifications.

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3.4.2 Wheel Installation On ø 32 mm
Forks With A ø 20 mm Through-
Hole Axle
For optimum fork performance, please follow the
instructions below when installing the wheel:
• Place the wheel in between each fork.
• Align the center of the wheel with each wheel
axle clamp (see 5A of Picture 5).
• Insert the axle through the wheel axle clamp
of the right fork, through the wheel, and then
through the wheel axle clamp of the left fork
(see 5A of Picture 5).
• Tighten the axle to the required torque (15±1
Nm) using a 6mm Allen key to the caps of the
axle (see 5B of Picture 5).
• Check for the proper fork-wheel alignment. To
do this, begin by fully compressing the fork a
few times. The wheel should not make
contact with, or come close to any portion of
the fork. Then lift the front of the bicycle and
spin the wheel a few times to verify the
correct alignment with the disk brake. The
wheel should not wobble from side to side or
up and down. Check the owner’s manual of
the brake system for the proper
specifications.
• Tighten the screw positioned on each wheel
axle clamp to the required torque (6±1 Nm)
(10±1 Nm for D-Street 24”) using a 4mm (5
mm for D-Street 24”) Allen key (see 5C of
Picture 5).
Picture 5 - Wheel installation on a ø32 mm forks with
aø20 mm through-hole axle
6 mm
15±1 Nm
5A
5C
5B
4 mm
6±1 Nm
5 mm
10±1 Nm
D-Street 24"

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3.4.3 Wheel Installation On 66 And 888
Series Forks
For optimum fork performance please follow the
instructions below when installing the wheel:
• Place the wheel in between each fork.
• Align the center of the wheel with each wheel
axle clamp (see 6A of Picture 6).
• Insert the axle through the wheel axle clamp
of the right fork, through the wheel, and then
through the wheel axle clamp of the left fork
(see 6A of Picture 6).
• Tighten the axle to the required torque (15±1
Nm) using a 6mm Allen key to the caps of the
axle (see 6B of Picture 6).
• Check for the proper fork-wheel alignment. To
do this, begin by fully compressing the fork a
few times. The wheel should not make
contact with, or come close to any portion of
the fork. Then lift the front of the bicycle and
spin the wheel a few times to verify the correct
alignment with the disk brake. The wheel
should not wobble from side to side or up and
down. Check the owner’s manual of the brake
system for the proper specifications.
• Tighten the screws positioned on each wheel
axle clamp to the required torque (6±1 Nm),
with a “1-2-1” sequence, using a 4mm Allen
key (see 6C of Picture 6).
Picture 6 - Wheel Installation on 66 end 888 series
forks
6 mm
15±1 Nm
4 mm
6±1 Nm
6A
6C
6B