Marzocchi SHIVER DC User manual

Shiver
DC
GENERAL RULES
1. Where specified, assemble and disas-
semble the suspension system using the
M ARZOCCHI special tools only.
2. On reassembling the suspension system,
always use new seals.
3. Clean all metal parts with a special,
preferably biodegradable, solvent such
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
in contact with each other using silicone
fat spray or specific seal oil.
5. Always grease the conic seal rings be-
fore reassembling.
6. Use wrenches with metric size only.
Wrenches with inch size might damage
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
7. If two screws are close one to the other,
always tighten using a 1-2-1 sequence.
In short, screw the first screw just up to the
point it is well tightened, then tighten the
second screw and then go back to the
first one and screw it tighter.
INSTRUCTIONS

Shiver
DC
FAILURES, CAUSES AND REMEDIES
This paragraph reports some troubles that may occur when using the fork. It also indicates possible causes and suggests a remedy. Always
refer to this table before doing any repair work.
Oil leaking through wheel shaft pinch bolt O-ring seal on the cartridge nut is
damaged
Replace the O-ring seal
Oil leaking through the dust seal. 1. Oil seal is worn out
2. Stanchion tube is scored
3. Excessive dirt on slider oil seal
1. Replace oil seal
2. Replace oil seal and stanchion tube/
wheel shaft pinch bolt assembly
3. Clean the oil seal seat and replace oil
seal and dust seal
Fork has not been used for some time
and is locked out
Oil seals and dust seals tend to stick to
stanchion tube
Raise dust seal and lubricate stanchion
tube, oil seal and dust seal
Fork compresses and/or rebounds too
fast even though the adjuster is set to
hardest damping position
Hydraulic cartridge is faulty Replace hydraulic cartridge
FAILURES CAUSES REMEDIES
Adjuster position does not affect fork
operation
Dirt inside legs Clean carefully and change oil
Excessive play of stanchions into the
sliders
Main slider bushings are worn Replace main slider bushings

Shiver
DC
3
3
Nm11
RECOMMENDATIONS FOR
MAINTENANCE
M ARZOCCHI forks are based on advanced
technology, supported by year-long experi-
ence in the field of professional mountain
biking. In order to achieve best results, we
recommend to check and clean the area
below the dust seal and the stanchion tube
after each use and lubricate with silicone
oil.
In general, M ARZOCCHI forks can offer top
performance from the start. However, in
some cases a short running-in period is
required (5-10 hours) for inner adjustments.
This running-in period will make fork life
longer and ensure fork top performance
over time.
IMPORTANT: change oil at least every
100 operating hours.
INSTALLATION
Installing a SHIVER on a bicycle is a very
delicate operation that should be carried
out with extreme care.
• The installation should always be checked
by an authorized Service Center.
WARNING: steering tube must be
installed and adjusted in compliance
with manufacturer’s instructions. Improper
installation may jeopardize the safety of the
rider.
• The fork is supplied with “A-Head set”
steering tube to be cut according to
frame length.
• The steering tube is pressed into the
crown. To replace it, contact an author-
ized Service Center that will use the
required tools.
WARNING: in case of improper
installation of the steering tube into
the lower Crown, the rider might lose con-
trol of his/her bicycle, thus jeopardizing
his/her safety.
FITTING FORK ONTO THE FRAME
• Check the tightening torque of the retain-
ing screws (3) before installing the fork
to the frame.

Shiver
DC
26
A A
D
B
36-39
E
D
C
3
3
Nm11
• Distance “D”between lower Crown
and tyre edge (when inflated) should not
be lower than 193 mm (total travel + 3
mm).
WARNING: if lower Crown is im-
properly matched with sliders, it may
touch the tyre and cause severe injuries to
the rider.
• When fitting the slider onto the lower
Crown, step (A) corresponding to outer
diameter variation must be as high as or
be higher than the most inner contact
point (B) between lower Crown (26)
and sliders.
• Assemble the fork to the frame complete
with headset.
• Fit the upper crown (36) and (39) into
the upper sliders and the steering tube.
• Ensure that upper surface (C) is as high
as or higher than the most inner contact
point (D) between upper crown (36)
and (39) and sliders.
• If fork legs overprotrude, fit some spac-
ers (E) to the plate close to the steering
tube.
• If the lower Crown position with respect
to the sliders has been changed for any
reason, adjust the original distance (D).
• Tighten the retaining screws (3) holding
the sliders to the lower Crown to the
specified torque.
WARNING: do not overtighten the
screws (3) as this may distort the
stanchions and weaken the whole structure.

Shiver
DC
Nm11
3
3
36-39
3
3
38
37-25
36-39
Nm11
Nm11
• Now finally tighten the screws (3) on the
upper crown (36) or (39) to the speci-
fied torque.
• Position lower handlebar support (37)
or (25) onto the upper crown (36) or
(39) ; holes must be aligned.
•Secure the above two parts together by
means of the screws (3) . Tighten the
screws to the specified torque.
•Fit the handlebar: center in handlebar
support and lock by means of upper bolt
(38) and the screws (3); tighten the
screws to the specified torque, working
crossways.
DISC BRAKE SYSTEM ASSEMBLY
Assembling the brake caliper onto the wheel
shaft pinch bolts is a very delicate operation
that should be carried out with extreme
care.
Improper assembly might overstress the
caliper supports which might break.
This system should be installed by special-
ized technicians in a position to fully under-
stand and properly follow the instructions
given by the manufacturer.

Shiver
DC
21A
21B
Nm20 Nm63
FITTING WHEEL
•Insert the complete wheel assembly be-
tween the legs and fit the wheel shaft
(21A) into the wheel shaft pinch bolt
from the right hand side; push down until
it stops against the wheel hub.
•Tighten the wheel shaft screw (21B)
onto the LH to the specified torque.
•Compress the fork several times so the
legs will become properly seated onto
wheel shaft. Lock the screws (3) in the
wheel shaft pinch bolts to the specified
torque.

Shiver
DC
35
C
ADJUSTMENTS
SPRING PRELOAD
Turning the adjuster knob (35) on top of
fork legs to adjust preload of spring for
COMPRESSION damping. The fork is set to
the minimum preload at the factory, i.e. the
knob will be completely unscrewed coun-
terclockwise. However, the springs are
slightly preloaded to help counteract static
loads. By turning the knob clockwise, the
preload is increased up to the maximum
value equal to 15 mm of spring preload.
REBOUND
The adjuster screw (C) located on top of the
leg controls REBOUND damping. When
turning inside the cartridge rod, this ad-
juster will change the hydraulic configura-
tion of the inner valves. To adjust, always
start from the minimum damping setting,
i.e. with the screw fully turned counterclock-
wise.
IMPORTANT: do not force the adjuster
screw (C) over its limit.

Shiver
DC
35 33
34 10
32
31
18
ASSEMBLY INSTRUCTIONS
REMOVING UPPER CAP AND
SPRING
NOTE: leave fork legs secured to the lower
Crown to remove upper caps from sliders.
FIG. 1
Set the knob (35) to the minimum preload
position.
Loosen the grub screw (33) fastening the
preload knob by means of a 1.5 mm Allen
wrench. Remove grub screw from cap as-
sembly.
FIG. 2
Remove the stop ring (34) from the top of
the preload knob support (10) with a small
screwdriver.
WARNING: never use the fork with-
out upper cap otherwise the stan-
chion might detach from its slider.
FIG. 3
Remove the cap (32) with a 28-mm
socket wrench.
Remove the cap complete with O-ring (31)
from the slider (18).
Now the legs can be removed from the
lower Crown.

Shiver
DC
10
32
9
24
29
23
1
2
FIG. 4
Push down the outer slider onto the stan-
chion tube.
Lock the check nut (9) and remove the cap
(32) from hydraulic cartridge top (10).
FIG. 5
Push the stanchion tube into the slider and
remove the upper washer (29), the preload
sleeve (23) and the spring (24).
Remove all parts and let all the oil drain into
the fork leg. By following this procedure,
there is no need to check the oil level.
Make all necessary changes.
REMOVING HYDRAULIC
CARTRIDGE
FIG. 6
Let all the oil drain out.
WARNING: dispose of exhausted
oil in compliance with current laws.
To change the fork leg oil follow the proce-
dure as described at section FILLING WITH
OIL.
Remove the stanchion tube from the slider.
Turn the stanchion tube upside-down and
unscrew the foot nut (1) complete with O-
ring (2) using a 15 mm socket wrench.

Shiver
DC
12
14
15
FIG. 7
Pull the hydraulic cartridge (12) from stan-
chion tube top and make all necessary
changes.
NOTE: when supplied the hydraulic car-
tridge is complete with seals (see exploded
view), spring guide (8), check nut (9) and
preload knob support (10). These parts are
available also separately.
REMOVING GUIDE BUSHING AND
SEAL ASSEMBLY
FIG. 8
Turn the slider upside-down and remove the
dust seal (14).
FIG. 9
Remove the stop ring (15) from the slider
by placing the screwdriver bit in one of the
three openings on the stop ring and care-
fully lifting the ring out of place.
IMPORTANT: when removing the stop
ring, make sure not to damage slider inner
seat.

Shiver
DC
16
A
17
18
FIG. 10
Fit the slider protector (A) onto the slider
and remove the oil seal (16) with the help
of a large slot screwdriver.
IMPORTANT: when removing the oil seal,
make sure not to damage slider inner seat.
Once removed the oil seals should not be
used again.
FIG. 11
Remove bush washer (17) from the slider.
FIG. 12
To remove the guide bushing (19) and the
spacer (20), beat powerfully the slider
edge (18) on a wooden surface. Perform
this operation with extreme care and try to
keep the slider perpendicular to the wooden
surface. Use a bush puller in case of need
and do not scratch slider inner surface.
Make all necessary changes.

Shiver
DC
19
20
19
17
16
B
ASSEMBLING GUIDE BUSHING
AND SEAL ASSY
FIG. 13
Check that no dirt or debris is between
slider and bushing and grease with fork oil
all parts.
Fit the upper bushing (19) and use the
spacer (20) to push it into the slider.
Fit the other guide bushing (19). In case of
need, use the drift (B) to seat it into the
slider.
FIG. 14
Fit the bush washer (17) into the slider so
that it touches the guide bushing.
FIG. 15
Lubricate the oil seal (16) and place it onto
the drift (B) with the hollow side toward the
slider.
Press the oil seal into place until it touches
the bush washer by using the above drift.

Shiver
DC
15
14
14
FIG. 16
Insert the stop ring (15) and make sure it is
properly seated into place in the slider.
Use the drift (B) used previously to properly
seat the seal.
FIG. 17
Lubricate the dust seal (14) and insert it into
the stanchions from the spring end.
FIG. 18
Duly lubricate the stanchion tube and fit it
into the slider fully down. Insert the dust seal
(14) into the slider.

Shiver
DC
12
Nm11
1
2
12
80
RE- ASSEMBLING HYDRAULIC
CARTRIDGE
FIG. 19
Insert the hydraulic cartridge (12) com-
plete with seals and caps with the stanchion
pressed fully down into the slider.
FIG. 20
Grease the O-ring (2) on the foot nut (1)
and screw the nut on the hydraulic cartridge
threaded end.
Tighten to specified torque.
Pump stanchion up and down several times
to make sure it slides properly through the
stroke.
HOW TO FILL WITH OIL
FIG. 21
Pour the oil little by little when the slider is
fully down on the stanchion tube and then
pump with the cartridge (12) rod so as to
have a better filling.
Cartridge is full when no air is detected
when pumping, in the fully compressed
position (clockwise).
Check that the oil level is 80 mm from the
top of the slider in each leg.

Shiver
DC
24
29
23
10
32
9
32
31
Nm20
18
RE-ASSEMBLING SPRING AND
UPPER CAP
FIG. 22
Fit spring (24), preload sleeve (23) and
upper washer (29) in each fork leg.
FIG. 23
Move the plunger (30, see exploded view),
in the cap (32), to the minimum preload
position.
Screw the cap on preload knob support top
(10) until it rests against the check nut (9).
Lock the check nut (9) on cap (32) with the
wrenches used for disassembling.
FIG. 24
Lubricate the O-ring (31), lift slider (18)
and fit the cap (32) by hand.
Tighten the cap to the specified torque.

Shiver
DC
34 10
35 33
Nm1,5
FIG. 25
Fit the stop ring (34) of the preload knob
support (10) and make sure it is properly
seated into place.
WARNING: never use the fork with-
out this part otherwise the stanchion
might detach from its slider and cause
serious accidents.
FIG. 26
Fit the preload knob (35) and secure it on
the support (10) by tightening the grub
screw (33) to specified torque.
Now fit the fork legs onto the lower Crown
as described in “INSTALLATION”section.