Diy How To Service 888 Bomber Fork
Welcome to our comprehensive step-by-step tutorial on how to rebuild the Marzocchi Bomber 888 RC Fork, specifically for the 2009 model with 200mm of downhill travel. Suspension maintenance is crucial for optimal performance and longevity of your mountain bike, and rebuilding your fork is a rewarding skill to master. In this guide, we’ll provide detailed instructions, along with a list of materials and tools you’ll need to successfully rebuild your fork. Whether you’re a seasoned mechanic or a beginner enthusiast, this tutorial will walk you through each stage of the process, ensuring your Marzocchi Bomber 888 RC fork performs at its best on the trails.
Materials Needed:
- Socket and Wrench Set:
- Metric sizes: 5mm, 6mm, 8mm, 10mm, 13mm, 15mm, and 17mm sockets and wrenches.
- Suspension Fluid:
- 500ml of 10wt suspension oil for the damper side.
- 500ml of 7.5wt suspension oil for the spring side.
- Suspension Grease:
- 30ml of suspension-specific grease for lubricating seals, O-rings, and other components.
- Rebuild Kit:
- Includes seals, dust wipers, foam rings, O-rings, and any other necessary components specific to your fork model.
- Clean Rags:
- At least 5 clean, lint-free rags for cleaning components and wiping away excess oil and grease.
- Fork Oil Syringe:
- A 60ml syringe with a flexible hose attachment for accurately measuring and injecting suspension fluid into the fork.
- Suspension Pump:
- A high-quality suspension pump with a pressure gauge for adjusting air pressure in the fork (if applicable).
- Suspension-Specific Cleaner or Isopropyl Alcohol:
- A bottle of suspension-specific cleaner or isopropyl alcohol for cleaning components thoroughly before reassembly.
- Seal Pick or Small Flathead Screwdriver:
- A small flathead screwdriver or seal pick for removing old seals, O-rings, and dust wipers.
- Soft Mallet or Rubber Mallet:
- A soft mallet or rubber mallet for gently tapping components into place during reassembly.
- Plastic or Rubber Gloves:
- Disposable plastic or rubber gloves to protect your hands from chemicals and oils during the rebuild process.
Step-by-Step Tutorial:
- Prepare the Work Area:
- Set up a clean, well-lit workspace with enough room to lay out and organize components. Place a drain pan or container beneath the fork to catch any spilled oil.
- Remove the Fork from the Bike:
- Use a 5mm Allen key to remove the axle pinch bolts and a 6mm Allen key to remove the brake caliper bolts.
- Use a 6mm Allen key to loosen the stem bolts and carefully remove the fork from the frame.
- Drain the Fork:
- Unscrew the top caps of the fork legs using a 24mm socket or wrench and allow the oil to drain completely.
- Cycle the fork a few times to expel any remaining oil.
- Disassemble the Fork:
- Use a 24mm socket or wrench to remove the top caps from each leg.
- Carefully slide the stanchions out of the lowers, paying attention to any spacers, shims, or other small components.
- Clean and Inspect Components:
- Use suspension-specific cleaner or isopropyl alcohol and clean rags to thoroughly clean all parts.
- Inspect the stanchions for scratches, dents, or other damage. Replace if necessary.
- Check the bushings for wear and replace if necessary.
- Inspect the damper and spring assemblies for signs of damage or wear.
- Install New Seals, Dust Wipers, and Foam Rings:
- Apply suspension grease to the new seals, dust wipers, and foam rings.
- Carefully slide the new seals, dust wipers, and foam rings onto the stanchions, ensuring they are properly aligned and seated.
- Reassemble the Fork:
- Reinsert the stanchions into the lowers, taking care not to damage the seals or dust wipers.
- Reattach the top caps and tighten them to the manufacturer’s specifications using a 24mm socket or wrench.
- If applicable, reinstall any adjustment knobs or caps on the top of the fork legs.
- Refill with Oil:
- Consult your fork’s manual for the appropriate amount and viscosity of suspension oil for each leg.
- Use a fork oil syringe to fill each leg with the correct amount of oil.
- Reinstall the fork’s top caps and tighten them to the manufacturer’s specifications.
- Reinstall the Fork:
- Slide the fork back into the frame’s headset and tighten the stem bolts to the manufacturer’s specifications.
- Reinstall the brake caliper, handlebars, and axle, making sure everything is properly aligned and tightened.
- Test the Fork:
- Cycle the fork through its travel to ensure it moves smoothly and doesn’t bind.
- Check for any oil leaks or unusual noises.
- Adjust the rebound and compression settings according to your preferences and riding style.
- Final Check:
- Double-check all bolts and connections for tightness.
- Wipe down the fork to remove any excess grease or oil.
- Take your bike for a test ride to ensure everything is working properly and make any necessary adjustments.
By following these detailed steps and using the specified materials and tools, you should be able to successfully rebuild your 2009 Marzocchi Bomber 888 RC fork with 200mm travel. Always refer to the manufacturer’s instructions and specifications for the best results.