Norco FULL SUSPENSION BIKE Technical Manual

Photo: harookz.com Rider: Ben Boyko

NORCO
FULL SUSPENSION BIKE

TECHNICAL MANUAL

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TABLE OF
CONTENTS

INTRO

MAINTENANCE

SETTING UP YOUR NORCO
FULL SUSPENSION BIKE

TEAM DH

A-LINE/A-LINE PE

ATOMIK

SHORE 1, 2, 3

SIX SE, 1, 2, 3

FOUR X

FLUID SE, 1

FLUID 2, 3, 4

FAZE 1, 2, 3

ADDITIONAL INFORMATION

Photo: www.carroux.com Rider: Gareth Dyer

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INTRODUCTION

WHAT’S NEW FOR 2007

Building on our solid foundation of functional hardcore bikes we’ve
further improved all our full suspension models in key areas that riders
will appreciate. Frame geometry and rear suspension parameters have
been finely tuned to suit the intended application, whether it’s full-on DH,
freeride, or all-mountain and XC riding styles. Rest assured, our bikes will
continue to demonstrate their legendary toughness and durability under
real-world conditions.

DH/Extreme Freeride Models (Team DH, A-Line Park Edition,
A-Line, Atomik)

These models have undergone further weight reductions from last year
for improved performance without affecting durability. The Team DH
frame has a completely new race-focused frame design: lighter weight,
increased stiffness, and improved geometry ensure success for DH racers
of all skill levels. The new-for-2007 A-Line Park Edition, with its anodized
frame finish and upgraded component specs, joins the A-Line and Atomik
models to continue the tradition of exceptional performance, bulletproof
reliability, and great value.

Shore Freeride (Shore 1/2/3)

The 2007 Shore models continue to represent new-school freeride proudly.
The Shore 1 and 2 models feature revised geometry for better handling,
a new head tube design for increased front end stiffness, and revised
suspension linkage for better big-hit performance. The Shore 3 model
continues to offer outstanding performance, durability, and value in a
progressive package. All Shore models benefit from a new XS frame size.

All Mountain Freeride (Six SE/1/2/3)

The 2007 Six models continue to evolve into the ultimate “versatile” all­mountain platform that isn’t afraid to hang it out. New-for-2007 Fox DHX
air shocks on the Six 1 and 2 rival coil spring performance while reducing
weight. Further weight reductions in component specs make the 2007 Six
models the lightest ever.

All Mountain Cross-Country (Fluid SE/1.0/2.0/3.0/4.0)

The all-new 2007 Fluid SE and 1.0 models feature a further-improved
4-bar linkage suspension system, along with reduced frame weight,
increased travel, and even greater pedaling efficiency. All Fluid models
feature a new shaped top tube that reduces standover height to increase
fit options for riders of all sizes.

Cross-Country (Faze 1.0/2.0/3.0)

The new 2007 Faze platform features a 4-bar link suspension design
that delivers 96mm (3.8”) or 116mm (4.6”) of efficient wheel travel for
racing or really fast trail riding. Using the same design philosophy as the

Fluid SE/1.0 design, increased performance and efficiency are the results.
Coupled with high-performance components, the Faze models are the
lightest XC FS bikes ever offered by Norco.

Dirt/Street (Four X)

Continuing for 2007 is the Four X. With its race-inspired graphics and
solid performance, this model can do it all. With its efficient pedaling and
versatile geometry, Norco’s team riders use the Four X for racing, dirt
jumping, and Slopestyle events.

SUSPENSION

To take full advantage of your Norco full suspension bike, care must
be taken to ensure correct rear shock set-up, e.g. sag, rebound and
compression adjustments. Proper seat height when climbing and
descending also determines how well your bike performs.

MAINTENANCE

We can’t be with you on every ride, so we’ve put together some important
maintenance tips to help you keep your bike safe and ride-ready. We
also want you to enjoy your Norco bike for years to come; with simple
maintenance and rider responsibility you can have your favourite ride for
many years.

DESIGN

All Norco full suspension frames are analyzed and designed to provide the
best ride for their intended purpose. Few parts are shared between the
different models; although they look similar, they have been specifically
engineered for their intended purpose to give the correct amount of
suspension travel and “feel”.

Of course, the common thread in all these models is a four-bar linkage
design utilizing the patented FSR technology, or “Horst Link”. By using a
lower dropout pivot location, the design achieves a more vertical wheel
path and suspension performance remains active and consistent under
all conditions, whether accelerating or braking. Conventional wisdom
still maintains this technology is the standard to which all other designs
are measured. When performance, weight, rigidity, and reliability are
considered, our designs have few equals.

IN CLOSING

Norco Performance Bikes and its staff have taken great pride in delivering
home-grown bikes since 1964. While a lot has changed since then, our
commitment to excellence and our passion for cycling hasn’t. Please ride
responsibly and stay within your limits no matter how tempting a line or
trail may be. Always make it your goal to ride another day.

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Regular maintenance is crucial for safety and the longevity
of your bicycle. Your bike’s performance will be maximized
by performing proper pre-ride checks, monthly inspections,
and yearly overhauls. As fork maintenance is quite complex,
please refer to the fork manual included with your bike. Refer
to the following information regarding periodic maintenance
checks. This schedule is based on average use by an average
recreational rider not riding in a bike park setting.

BEFORE EACH RIDE

1. Ensure all shock and linkage bolts, crank bolts and stem
bolts are sufficiently tight.

2. Check if wheels are aligned straight in their dropouts.
Make sure the rear axle is fully in the dropouts. Check the
quick release and/or axle bolt for proper tightness. Refer
to the Norco manual for correct installation procedure.
Refer to your fork manual for correct front axle installation
procedure.

3. For disc brakes, make sure brake pads move freely when
brake lever is squeezed. If problems arise get your bike
inspected by a qualified Norco dealer. For V-brakes, spin the
wheel to ensure that pads do not contact the rim when the
brake lever is not squeezed. In both cases, unwanted pad
rub leads to premature wear and uneven braking. Always
make sure your brakes will stop your bike.

4. Clean drivetrain, and lightly lube chain. Excess lube attracts
grit and dirt.

5. Check to see if the headset is loose by applying the front
brake and rocking the bike back and forth. If you hear or
feel clunking (play) from the head tube area, your headset
could be loose. Tighten the headset or visit a qualified Norco
dealer for inspection.

6. For bikes that are equipped with dual crown forks, check to
see if bumpers stop stanchions from hitting the frame.

EVERY MONTH

1. Check for bearing wear. While the bike is in contact with the
ground, hold the rear wheel with one hand and seat post
with the other. Try to pull the wheel back and forth as well
as up and down. If you notice any looseness (play), bring
your bike to an authorized Norco dealer.

2. Check brake pad wear. For disc brakes, replace pads if pads
are approximately .5mm thick or less or are contaminated
with oil. For V-brakes, replace the pads if they are worn past
the wear line.

3. Check hydraulic brake lines for kinks and/or small
perforations. Check cables for corrosion. Replace leaking
hydraulic lines. Replace frayed or corroded cables for
improved performance.

ONCE A YEAR

1. Have a complete overhaul performed on your full suspension
bike by your authorized Norco dealer, consisting of hub,
bottom bracket, pivot assembly and brake overhauls.

2. Check drive-chain for wear. Replace if assessed worn out.

Note: If you are a user of mounta in b ike parks, lik e Whistler ’s, it is pr udent to go throug h st eps

1-5 o f th e pr e-ride che ck p art way throug h your day at the par k as this kin d of ter rain and
riding is extremely demanding. Pos t-ride mai ntenance m ust also be perfor med on a more
freque nt basis.

MAINTENANCE

SHOCK ASSEM BLY

MAIN F RAME P IVOT

CHAINST AY PI VOT

BB PI VOT

SEATSTA Y PIVO T

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SETTING UP YOUR NORCO FULL SUSPENSION BIKE

Note: For 4mm bolts (on Cro ss Country bik es) use
80 in ch p ounds (in- lb) 9 N. m

SWING LINK

SEAT TUB E

CHAIN STAY

SEAT STAY

1” PAS T SEA T TUBE

LOCATION BOLT SIZE TORQUE

SEATSTAY PIVOT 5MM (M6 ) 120 IN-LB / 15 N-M

MAINFRAM E PIVOT 5MM (M6 ) 120 IN-LB / 15 N-M

CHAINSTAY PIVOT 5MM (M6) 120 IN- LB / 15 N -M

SHOCK ASS EMBLY 5MM (M6) 120 IN- LB / 15 N -M

BB PIVO T 6MM (M8 ) 150 IN-LB / 17 N-M

TORQUE

REAR SHOCKS

Our bikes come pre-set for the average rider for the frame size in
question. Proper set-up of saddle height, saddle angle, and rear shock
settings is necessary for your safety as well as the bike’s performance.
Have your authorized Norco dealer adjust your bike properly to get the
best fit possible. Refer to the information below for the best set-up of
your Norco bike.

REAR SHOCK

To get the best performance from your rear suspension, the
rear shock must be adjusted according to your weight, riding
style and terrain. We recommend a rear shock set-up of
20-25% sag of total travel for cross-country/all-mountain
applications and 25-35% for freeride/downhill applications.
See the charts for specific lengths. For more information
refer to the shock manual supplied with your bike or visit the
manufacturer’s web site.

SEAT HEIGHT

Norco VPS bikes use an interrupted seat tube design. Seat posts
must not extend past the bottom of seat tube for extra-small and
small frames and no more than 1” past the seat tube for medium,
large, and extra-large frames. We suggest cutting your seat post to
the length that meets your desired style of riding; also you can
use a telescopic seatpost to get additional
saddle height if your bike was not equipped
with one originally. Please test your set-up
before riding to ensure there will be no
interference between the seat post and
the frame during full compression.

MODEL REAR SHOCK EYE-EY E LE NGTH WITH SAG

TEAM D H MARZOCC HI ROC O WORLD CUP : 9.5" X 3 .0" 8.75" (222MM) - 2 5% SAG 8.6" ( 218MM) - 30 % SAG 8.5" ( 216MM) - 35 % SAG

A-LINE PARK EDI TION MARZOCCHI ROCO TST R: 9.5" X 3.0" 8.75" (222MM) - 2 5% SAG 8.6" ( 218MM) - 30 % SAG 8.5" ( 216MM) - 35 % SAG

A-LINE FOX DH X-3: 9.5" X 3.0" 8.75" (222MM) - 2 5% SAG 8.6" ( 218MM) - 30 % SAG V8.5" (216MM) - 3 5% SAG

ATOMIK FOX DH X-3: 8.75" X 2.75" 8.06" (205MM) - 2 5% SAG 7.9" ( 201MM) - 30 % SAG 7.88" (200MM) - 3 5% SAG

SHORE 1 MA RZOCCHI ROCO TST R / FO X DHX-5: 8. 5" X 2.5" 7 .88" (200MM) - 25% SAG 7 .75" (197MM) - 30% SAG 7 .63" (194MM) - 35% SAG

SHORE 2 FO X DHX-3: 8. 5" X 2.5" 7. 88" (200MM) - 25% SAG 7. 75" (197MM) - 30% SAG 7. 63" (194MM) - 35% SAG

SHORE 3 FO X VAN R: 8.5" X 2.5" 7.88" (200MM) - 25% SAG 7.75" (197MM) - 30% SAG 7.63" (194MM) - 35% SAG

SIX SE FOX DH X AIR 5.0: 7. 875" X 2.25 " 7.43" (189MM) - 2 0% SAG 7.31" (186MM) - 2 5% SAG 7.2" ( 183MM) - 30 % SAG

SIX 1 FOX DH X AIR 4.0: 7 .875" X 2.25" 7.43" (189MM) - 2 0% SAG 7.31" (186MM) - 2 5% SAG 7.2" ( 183MM) - 30 % SAG

SIX 2 FOX DH X AIR 3.0: 7 .875" X 2.25" 7.43" (189MM) - 2 0% SAG 7.31" (186MM) - 2 5% SAG 7.2" ( 183MM) - 30 % SAG

SIX 3 FOX VAN R: 7.875" X 2.25" 7.43" (189MM) - 2 0% SAG 7.31" (186MM) - 2 5% SAG 7.2" ( 183MM) - 30 % SAG

FLUID SE, 1 FOX FLOAT RP23: 7.875 " X 2.0" 7.48" (190MM) - 2 0% SAG 7.38" (187MM) - 2 5% SAG 7.28" (185MM) - 3 0% SAG

FLUID 2, 3 FOX FL OAT R: 7. 875" X 2.0" 7.48" (190MM) - 2 0% SAG 7.38" (187MM) - 2 5% SAG 7.28" (185MM) - 3 0% SAG

FLUID 4 FOX FL OAT: 7.875" X 2.0" 7.48" (190 MM) - 20% SAG 7.38" (187 MM) - 25% SAG 7.28" (185 MM) - 30% SAG

FAZE 1, 2 FOX FL OAT RP23: 7.875" X 2 .0" 7.48" (190MM) - 2 0% SAG 7.38" (187MM) - 2 5% SAG 7.28" (185MM) - 3 0% SAG

FAZE 3 FOX FL OAT R: 7. 875" X 2.0" 7.48" (190MM) - 2 0% SAG 7.38" (187MM) - 2 5% SAG 7.28" (185MM) - 3 0% SAG

4XXXX FOX FL OAT R: 7. 875" X 2.0" 7.48" (190MM) - 2 0% SAG 7.38" (187MM) - 2 5% SAG 7.28" (185MM) - 3 0% SAG