Attn Fellow Suspension Nerds - 180mm Zeb won't get full travel?

12/7/2023 2:05am
ebruner wrote:
likely not what you want to hear... but I wouldn't be running a zeb at 150lbs unless I was a world cup level rider and capable...

likely not what you want to hear... but I wouldn't be running a zeb at 150lbs unless I was a world cup level rider and capable of putting energy into the bike like a 190-200lb expert pro-am rider.  

That being said... the zeb is a great chassis and with some mods it can be excellent, even for light weight riders.  Burnish the bushings, add a vorsprung secus, install a softer midvalve/checkvalve shim and run hsc all the way open.  This should get you close to ideal.  

I wish I knew that before. The zeb comes with a complete bike. 

When you are shopping for a enduro bike with <64 HA, they usually come with a 170 fork. I wish there are more enduro bikes using 160mm

9/3/2024 5:09pm
Rumlan wrote:
After many years on Fox i've got a bike built up this season with Rockshox suspension. Super deluxe coil shock is sorted but I have the...

After many years on Fox i've got a bike built up this season with Rockshox suspension. Super deluxe coil shock is sorted but I have the new 180mm Zeb Ultimate with the charger 3 damper and can't get full travel out of the thing.

TL:DR: Doesn't seem to matter what pressure or how many spacers the o-ring is always stopping 25mm from full travel. Is this just the way Zeb performs; hits a wall of pressure at 25mm from full travel or has anyone heard of specific issues with the internals that would cause it?

Detailed version:

- I'm 6.2' / 225lbs in my riding gear which has the RS app suggest 80psi in the fork.

- the 180mm Zeb ultimate with charger 3 damper is a brand new fork; about a month old with ~400km of hard DH/Enduro riding on it including 3x whistler days, shuttles, etc so should be well broken in.

- I've ridden the fork from 83psi down to 73psi dropping 2 psi at a time and have also tried 0,1 & 2 spacers while running laps on the same DH trails to see if I can get full travel.

- I didn't go below 73psi because fork was just way too soft to ride confidently by that point.

- HSC full open & LSC 4 from full open/soft.

- Changes to pressure and/or spacers make very large & noticeable changes to the way the fork rides in the usable 155mm of travel but every run, regardless of what my settings are, the o-ring is always exactly 25mm from full travel! With one exception...

- There's an 8 foot drop to flat that I was sessioning trying to get full travel and I was able to get to 13mm from full travel on this feature. It's brutally hard hit and changing the number of spacers didn't seem to change things in end stroke; 0 or 2 spacers would still only get me to 13mm from full travel. It's a brutal compression so should absolutely be able to bottom the fork on this feature (no problem bottoming here when I was on the Fox 38...was actually the oposite, trying to tune the ramp up so I could hit this feature without bottoming so harsh the fork clacks).

-  I've aired down the Zeb completely and cycled it to full travel to make sure there wasn't a mechanical stop or something. The fork also has the bleeder valves on the lowers which i've made sure i'm using to ensure it's not an equalization issue between the positive & negative chambers.

First post and it's a long one but if you've made it this far i'm super curious if this just the way it is with the 180mm Zeb or if someone else out there has come across this and found a specific issue preventing full travel?

Cheers

 

Did you ever get an answer to your question? 

I just want to share, I have 2 Zeb ultimates with buttercup stock. one is a 170mm and the other is 180mm. A few months back, I also got the issue where my forks can't reach past 25mm below the max travel line on the stanchions. I tried letting all the air out by pressing the pin on the valve core but still the same.

 

Last night, I removed the valve core and pressed the bleed valve on both lowers while applying a slight downward pressure on the handlebar and viola, the fork reach full travel, it even passed the max travel line on the stanchion a bit.

rpsteiger
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9/6/2024 1:27am

Hello everyone,
I read through all of the messages in this thread and it has been very helpful, by pointing out the options to make the fork less progressive.

My fork is a MY 23 Zeb Ultimate and I haven't been able to get it too work 'right' in two seasons of riding. I weigh 80 kilos and have been trying my best to become fast enough to keep pace at my local enduro races. The best setup I have found so far is 70 psi and zero tokens -- compression doesn't seem to matter that much imo; I usually leave it in the middle or fully open 🤷‍♂️
Other people here were able to perfectly explain what is happening (on some rides): deeper in the travel, at around 150 - 160 mm, I hit a wall of compression that I can't deal with. My local trails are mostly just extremely steep and I don't seem to hit the wall there. But this week I went into the alps and here it became oh so apparent. Lots of deep steps and large rocks. When I try to plow through these I hit the wall, hard. I ran an experiment mid trail: I set the air spring to 55 psi. That allowed me to plow through the same section, as mentionend before here,  but left me with a poor ride height. Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that.

Here's my todo list for getting the fork to work better for me:
- checking the airspring for excess grease -- I can do this myself once I get home
- I will install fresh SKF seals and make sure that I have the proper 7wt oil volume -- I can do this myself too, once I get home
- I contacted SRAM support. I will let you know what they tell me
- I ordered the Trutune. Atm the only have the short one
- At the end of september, I wil have my charger upgraded to the charger 3.1. I am curious what that will do to the fork
- I will check my bushing. Can I do the burnishing myself? Or should I have my local service center do that? How is that done? I am curious 

I am a big fan of rockshox products. Hopefully, I can get this fork to work for me, somehow. But unfortunately, this fork has not worked at all for me during the last two season and all this time I was convinced that I just suck Sad

Eoin
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9/6/2024 1:42am

It is most likely just air build up in your lowers, if you open up the bolts at the bottom (with 0 psi in main chamber), you might see results straight away. Then you might need to take some of the steps you mention to prevent the fork from getting harsh again over time.

I last did this at the start of the year and my fork was great until the end of summer, I went to a bike park 2 weeks ago at 2000m of altitude and could not get the fork past 160mm travel (180mm version). 

Jakub_G
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9/6/2024 6:15am
rpsteiger wrote:
Hello everyone,I read through all of the messages in this thread and it has been very helpful, by pointing out the options to make the fork...

Hello everyone,
I read through all of the messages in this thread and it has been very helpful, by pointing out the options to make the fork less progressive.

My fork is a MY 23 Zeb Ultimate and I haven't been able to get it too work 'right' in two seasons of riding. I weigh 80 kilos and have been trying my best to become fast enough to keep pace at my local enduro races. The best setup I have found so far is 70 psi and zero tokens -- compression doesn't seem to matter that much imo; I usually leave it in the middle or fully open 🤷‍♂️
Other people here were able to perfectly explain what is happening (on some rides): deeper in the travel, at around 150 - 160 mm, I hit a wall of compression that I can't deal with. My local trails are mostly just extremely steep and I don't seem to hit the wall there. But this week I went into the alps and here it became oh so apparent. Lots of deep steps and large rocks. When I try to plow through these I hit the wall, hard. I ran an experiment mid trail: I set the air spring to 55 psi. That allowed me to plow through the same section, as mentionend before here,  but left me with a poor ride height. Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that.

Here's my todo list for getting the fork to work better for me:
- checking the airspring for excess grease -- I can do this myself once I get home
- I will install fresh SKF seals and make sure that I have the proper 7wt oil volume -- I can do this myself too, once I get home
- I contacted SRAM support. I will let you know what they tell me
- I ordered the Trutune. Atm the only have the short one
- At the end of september, I wil have my charger upgraded to the charger 3.1. I am curious what that will do to the fork
- I will check my bushing. Can I do the burnishing myself? Or should I have my local service center do that? How is that done? I am curious 

I am a big fan of rockshox products. Hopefully, I can get this fork to work for me, somehow. But unfortunately, this fork has not worked at all for me during the last two season and all this time I was convinced that I just suck Sad

It ramps quicky because spring rate gets firmer deeper in the stroke as all chambers get smaller and smaller (air spring, left and right lower leg). Bushing burnishing is not hard if you have the tool and I guess you don't so that is that. It makes a big difference, yes. But running too soft air spring to compensate for something else is always compromise that is not worth it as it makes more things worse than better.

Primoz
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9/6/2024 7:41am

@rpsteiger "Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that."

The lower the pressure, the lower (deeper in the travel) your sag, both static and dynamic (dynamic ride height) will be. As air springs are naturally somewhat progressive, no matter how well developed they are, that just means you are operating in the progressive part of the characteristic vs. when running a higher pressure. That of course means that a given bump will be handled by less travel as the force will ramp up quicker.

It has been discussed in the past here on Vital, probably mentioned by either Darren Murphy from Push on Vital MTB podcast or by Jordi in Fox's Dialed series (or both actually), etc., but if you feel your fork is too stiff or harsh, removing the pressure is quite likely not the right way to solve things. Adding pressure is the correct way. This raises your ride height and moves you to a more linear part of the air spring. Opening rebound damping can also help as it enables the fork to rebound higher in the travel and not get packed down in the more progressive part of the travel.

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rpsteiger
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9/6/2024 8:12am
Primoz wrote:
@rpsteiger "Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that."The lower the pressure, the...

@rpsteiger "Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that."

The lower the pressure, the lower (deeper in the travel) your sag, both static and dynamic (dynamic ride height) will be. As air springs are naturally somewhat progressive, no matter how well developed they are, that just means you are operating in the progressive part of the characteristic vs. when running a higher pressure. That of course means that a given bump will be handled by less travel as the force will ramp up quicker.

It has been discussed in the past here on Vital, probably mentioned by either Darren Murphy from Push on Vital MTB podcast or by Jordi in Fox's Dialed series (or both actually), etc., but if you feel your fork is too stiff or harsh, removing the pressure is quite likely not the right way to solve things. Adding pressure is the correct way. This raises your ride height and moves you to a more linear part of the air spring. Opening rebound damping can also help as it enables the fork to rebound higher in the travel and not get packed down in the more progressive part of the travel.

Thank you for your reply. Exactly what you say is what I expected to happen: the deeper I run into the travel (deeper with 55 psi), the harder I should experience the end of stroke. Paradoxically, in my experiment the opposite happened. The fork feels way less progressive when riding through rock gardens on 55 psi, compared to 70. Obviously, there is no point in running the fork at 55 psi, since the ride height is poor. 

rpsteiger
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9/6/2024 8:13am
rpsteiger wrote:
Hello everyone,I read through all of the messages in this thread and it has been very helpful, by pointing out the options to make the fork...

Hello everyone,
I read through all of the messages in this thread and it has been very helpful, by pointing out the options to make the fork less progressive.

My fork is a MY 23 Zeb Ultimate and I haven't been able to get it too work 'right' in two seasons of riding. I weigh 80 kilos and have been trying my best to become fast enough to keep pace at my local enduro races. The best setup I have found so far is 70 psi and zero tokens -- compression doesn't seem to matter that much imo; I usually leave it in the middle or fully open 🤷‍♂️
Other people here were able to perfectly explain what is happening (on some rides): deeper in the travel, at around 150 - 160 mm, I hit a wall of compression that I can't deal with. My local trails are mostly just extremely steep and I don't seem to hit the wall there. But this week I went into the alps and here it became oh so apparent. Lots of deep steps and large rocks. When I try to plow through these I hit the wall, hard. I ran an experiment mid trail: I set the air spring to 55 psi. That allowed me to plow through the same section, as mentionend before here,  but left me with a poor ride height. Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that.

Here's my todo list for getting the fork to work better for me:
- checking the airspring for excess grease -- I can do this myself once I get home
- I will install fresh SKF seals and make sure that I have the proper 7wt oil volume -- I can do this myself too, once I get home
- I contacted SRAM support. I will let you know what they tell me
- I ordered the Trutune. Atm the only have the short one
- At the end of september, I wil have my charger upgraded to the charger 3.1. I am curious what that will do to the fork
- I will check my bushing. Can I do the burnishing myself? Or should I have my local service center do that? How is that done? I am curious 

I am a big fan of rockshox products. Hopefully, I can get this fork to work for me, somehow. But unfortunately, this fork has not worked at all for me during the last two season and all this time I was convinced that I just suck Sad

Jakub_G wrote:
It ramps quicky because spring rate gets firmer deeper in the stroke as all chambers get smaller and smaller (air spring, left and right lower leg)...

It ramps quicky because spring rate gets firmer deeper in the stroke as all chambers get smaller and smaller (air spring, left and right lower leg). Bushing burnishing is not hard if you have the tool and I guess you don't so that is that. It makes a big difference, yes. But running too soft air spring to compensate for something else is always compromise that is not worth it as it makes more things worse than better.

Thabk you for your reply. They have the proper tool in my local bike shop. I will report back afterwards 👍

rpsteiger
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9/6/2024 8:15am
Eoin wrote:
It is most likely just air build up in your lowers, if you open up the bolts at the bottom (with 0 psi in main chamber)...

It is most likely just air build up in your lowers, if you open up the bolts at the bottom (with 0 psi in main chamber), you might see results straight away. Then you might need to take some of the steps you mention to prevent the fork from getting harsh again over time.

I last did this at the start of the year and my fork was great until the end of summer, I went to a bike park 2 weeks ago at 2000m of altitude and could not get the fork past 160mm travel (180mm version). 

Thank you for your reply. I don‘t quite understand what you mean with air build up. I should be able to remove that by pressing thw bleed ports. Also my issues with the progression have remained constant over two years. Even after a full rebuild it was there. 

RGTec
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9/6/2024 12:40pm

Can someone explain to me why the very low pressure would affect the progression? I don't fully understand that.

Technically the progression is always the same regardless of pressure. As you said, at lower pressure you have more access to full travel but the mid stroke is also less supportive. So the difference between the mid and end stroke is about the same at both pressure settings. 

To change that requires increasing the size of the positive chamber. Trutune and the Luft Fusion are two ways to do that. They can also work togheter very well, I have some customers using both on the ZEB and their feedback suggests the LF is more effective for linearizing the travel, and not just the end stroke.

Jakub_G
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9/6/2024 1:21pm
rpsteiger wrote:
Thank you for your reply. I don‘t quite understand what you mean with air build up. I should be able to remove that by pressing thw...

Thank you for your reply. I don‘t quite understand what you mean with air build up. I should be able to remove that by pressing thw bleed ports. Also my issues with the progression have remained constant over two years. Even after a full rebuild it was there. 

It will be there unless you close off the lowers in compressed position. Or press the bleeders with fork compressed (with rag covering them so oil won't squirt on your.brake rotor/caliper)

rpsteiger
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9/7/2024 1:45pm

@Eoin @Jakub_G: there was air in the lowers. After letting out all the air and then pressing the bleed ports (while slightly pressing on the crown) the fork finally reached full travel 😄 You guys were right.

Garry17
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9/7/2024 2:51pm
Dave_Camp wrote:
Have you serviced the lower leg oil?  Too much lube oil can add a bunch of casting ramp.   I run zeb 180 at 70 psi...

Have you serviced the lower leg oil?  Too much lube oil can add a bunch of casting ramp.

 

I run zeb 180 at 70 psi, no tokens, 165 lbs and can bottom once in a while. 

Also worth doing a lower leg service to remove all the machining swarf left in them.

I have never seen this in any brand of fork, have you actually seen this or just heard of it? A lowers service is still worthwhile...

I have never seen this in any brand of fork, have you actually seen this or just heard of it?

A lowers service is still worthwhile, and check that the bushings are sliding freely. Forks don't really "break in" much in the early stages apart from a small amount of seal friction or just distributing grease/oil around the place. Over a year or two they can become smoother but if things like the bushings are too tight, it won't really improve. Also make sure no ones gone in and wiped away too much grease from the air spring because they heard from some insta-suspension-tech that forks have too much grease in them from factory (this hasn't been a problem for MANY years now). I've opened a lot of bone-dry air springs recently because of this that felt terrible.

 

The main thing though is 25mm left over is totally fine. If the rest of the travel works great then pay no attention to it. Suspension works in ways that are very counter-intuitive so there are lots of reasons it might not reach the end of the travel, even if you set it up quite soft. For example dropping the pressure right down will encourage higher damper speeds so the damper will soak up alot of the energy in the first half of the stroke, meaning there isn't much left to compress it the rest of the way. Then if you make it stiffer its just purely spring force preventing full bottom out. So the 2 settings give the same total travel used, its just for different reasons. Allthough bear in mind that the "stiffer" setting has more travel available so is travelling further before it reaches that end point too.

 

180mm is a lot of travel so you shouldn't really be needing all of it most of the time. Getting to the end of the stroke doesn't mean its working any better and in most cases is probably less than optimum. I personally expect to see around 10-20% left in "reserve" that may never get used but I do sometimes find that over time I will randomly encounter a place that does it. Just don't let it guide how you set up your fork

 

Swarf in new forks is a thing alright... I bought 2 x bikes with Rockshox at the start of the year (Zeb and Sid) and this is what was inside brand new forks. Had better pictures but can't find them on my phone...might be on my DSLRIMG 20240313 202724IMG 20240223 192011 0IMG 20240223 191950 0IMG 20240223 191824 0IMG 20240223 185419 0IMG 20240223 185412 0.jpg?VersionId=v1PRZv3e2S.S

rpsteiger
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9/8/2024 5:28am

Small update on my troubleshooting quest. I removed the lowers today. The air spring looks fine. There does not seem to be excess grease on the air spring, see the images below.

However, it was very hard to remove the lowers. I had to hammer lots on the screw to get it loose. I wonder if that is an indication of tight lower bushings 🧐

airspring2airspring1
Primoz
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9/9/2024 2:49am

"I had to hammer lots on the screw to get it loose. I wonder if that is an indication of tight lower bushings" 

It is not.  

rpsteiger
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9/14/2024 12:47am

Hi everyone
Yesterday, I received my trutune insert and managed to go for a short ride. The conditions weren't optimal: it was greasy and dark.
Installation was super straight forward and quick. As advertised, it behaves like a token.
The trutune does exactly what it said it would, it's quite mind boggling to me. It completely transformed the fork. Straight away, it felt way better 🥳
I did not hit a wall of progression in the mid stroke. I had to reduce the stack height, which I did not expect.
I will need some more time to trust the fork completely. I only tried one air spring setup: I went straight to 74 psi (from 70), which felt great. The damper setup felt perfect with LSC in the middle and HSC at minus 1.

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rpsteiger
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9/24/2024 11:02pm

Quick update: unfortunately I was not able to do more riding in the meantime. I am currently on holiday with my wife. I brought the zeb to a shop for bushing burnishing and also had them install the charger 3.1 upgrade kit. I will report back after my first ride with those changes. 

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rpsteiger
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10/13/2024 7:45am Edited Date/Time 10/22/2024 1:55am

I got the fork back from my shop. They
- burnished the bushings (only on one side the other was fine)
- upgraded the charger damper to charger 3.1—charger 3.1 should come with more oil flow for HSC. This is visible apparent when comparing the two thingies—I dont' know what that thing is called.
- I did not request it but they went with 5wt Motorex oil instead of 7wt Maxima Plush.

On the first ride, I tested the upgraded fork without the trutune insert at 70 psi. The initial impression was that it felt less harsh on square hits. On charger 3.0 I liked HSC at -1 but on charger 3.1, I prefer -2. Overall, I was under the impression that the change to the damper made the fork ride better, but it still felt too progressive.
Today I went on another ride with the trutune insert at 74 psi. I kept compression and rebound the same. I will need more testing but it feels pretty smooth now. Maybe I can lower the pressure with the trutune even further to 72 psi, I will see where that puts my sag at. I only measured sag without trutune at 70 psi which came out to 22-24%. Because of that I am scared of dropping my pressures lower.

To conclude: I think both the trutune and the charger upgrade make the fork better. I think you definitely want the charger upgrade, since it really helps with the harshness from square hits. The trutune really helps with the very progressive nature of the fork, but that might not be a problem for all riders.

EDIT: Two days ago, I tested my friend's Fox 38. It felt a lot less harsh in the mid to end stroke. Basically, it had exactly the feeling that I can't get out of my Zeb. I am pretty gutted at this point. I could still geld the lighter tune for the charger 3.1. However, I think the problem is the air spring ...

After going mad, I was looking online for information how the pro's run their Zeb. I came across this clip where Jack Moir says that he runs a light tune on this 2023 Zeb.

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TEAMROBOT
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11/25/2024 7:38am

We did it! Complain enough and someone will listen.

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Primoz
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11/25/2024 10:13am

What does the downtube say? 

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RGTec
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11/25/2024 10:29am
rpsteiger wrote:
I got the fork back from my shop. They- burnished the bushings (only on one side the other was fine)- upgraded the charger damper to charger...

I got the fork back from my shop. They
- burnished the bushings (only on one side the other was fine)
- upgraded the charger damper to charger 3.1—charger 3.1 should come with more oil flow for HSC. This is visible apparent when comparing the two thingies—I dont' know what that thing is called.
- I did not request it but they went with 5wt Motorex oil instead of 7wt Maxima Plush.

On the first ride, I tested the upgraded fork without the trutune insert at 70 psi. The initial impression was that it felt less harsh on square hits. On charger 3.0 I liked HSC at -1 but on charger 3.1, I prefer -2. Overall, I was under the impression that the change to the damper made the fork ride better, but it still felt too progressive.
Today I went on another ride with the trutune insert at 74 psi. I kept compression and rebound the same. I will need more testing but it feels pretty smooth now. Maybe I can lower the pressure with the trutune even further to 72 psi, I will see where that puts my sag at. I only measured sag without trutune at 70 psi which came out to 22-24%. Because of that I am scared of dropping my pressures lower.

To conclude: I think both the trutune and the charger upgrade make the fork better. I think you definitely want the charger upgrade, since it really helps with the harshness from square hits. The trutune really helps with the very progressive nature of the fork, but that might not be a problem for all riders.

EDIT: Two days ago, I tested my friend's Fox 38. It felt a lot less harsh in the mid to end stroke. Basically, it had exactly the feeling that I can't get out of my Zeb. I am pretty gutted at this point. I could still geld the lighter tune for the charger 3.1. However, I think the problem is the air spring ...

After going mad, I was looking online for information how the pro's run their Zeb. I came across this clip where Jack Moir says that he runs a light tune on this 2023 Zeb.

ZEB 2023

 

And a comparison with the Fox 38:

ZEB LF vs 38 0
1
11/25/2024 10:33am Edited Date/Time 11/25/2024 10:34am
Primoz wrote:

What does the downtube say? 

It says smack! My thoughts exactly. From MRP:

"The Noken is 10-13mm taller than standard damper control knobs, so it’s important to confirm downtube clearance before installation"

Looks like MRP ntoiced too https://mrpbike.com/products/riser-crown-race

NoahColorado
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11/25/2024 11:42am
It says smack! My thoughts exactly. From MRP:"The Noken is 10-13mm taller than standard damper control knobs, so it’s important to confirm downtube clearance before installation"Looks...

It says smack! My thoughts exactly. From MRP:

"The Noken is 10-13mm taller than standard damper control knobs, so it’s important to confirm downtube clearance before installation"

Looks like MRP ntoiced too https://mrpbike.com/products/riser-crown-race

I haven't seen a problem yet though. Here's two of my bikes for reference. Regular crown races.

Noken 38 Clearance.jpg?VersionId=i4taaEHv0OLVNonF65v0EyQaz0uNoken Zeb Clearance
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rpsteiger
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11/25/2024 11:50am

It's interesting that MRP came out with a product too. I am beyond confused on the topic of the newer RockShock stuff. Since my last post I bought a Manitou Mezzer and it is a lot better. I was able to set it up well in three rides and my bike rides balanced for the first time in 1.5 years.
At that point, I was convinced that my Zeb had been defect all this time. I sent it back to the factory, but they sent it back without any useful message (the warranty just expired 2 months ago). It would have liked to know whether is was fine or not, but I understand why they sent it back.

I hope I get an opportunity to borrow another Zeb from my shop to ride on my bike. It is highly unlikely that I will choose it over my Mezzer, but I would really like to know if the current Zeb is super harsh — and I would say unusable for most riders.

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Primoz
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11/25/2024 1:20pm

Have you checked for lowers binding? 

Post a reply to: Attn Fellow Suspension Nerds - 180mm Zeb won't get full travel?

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