Marzocchi Dirt Jumper 1,5 QR20 Bedienungsanleitung

Dirt

Jumper

1,5

QR20

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system us-

ing 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 a specific oil for seals.

5. Always grease the lip seal rings before

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.

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Jumper

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FAILURES, CAUSES AND REMEDIES

This paragraph reports some failures 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.

FAILURES CAUSES REMEDIES

Oil leaking though the top of slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on oil seal

1. Replace oil seal

2. Replace crown/stanchions assembly, oil

seals and dust seals

3. Clean the oil seal seat and replace oil seal

Oil leaking through the bottom of slider O-rings at pumping rod bottom damaged Replace the O-rings

Fork has not been used for some time and

is locked out

Oil seals and dust seals tend to stick to

stanchions

Raise dust seal and lubricate stanchion

tube, dust seal and oil seal

Excessive play of stanchions in the sliders Pilot bushings are worn Replace pilot bushings

Adjuster position does not affect fork

operation

Dirt inside legs Clean carefully and change oil

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RECOMMENDATIONS FOR

MAINTENANCE

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 working hours.

Polished forks should be cleaned with

bodywork polish at regular intervals in

order to preserve their original finish.

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DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake system

is installed, it is absolutely forbidden

to loosen and remove original brake sup-

ports fixing pins. In fact, apart from retain-

ing Cantilever or V-brake levers, they also

play an important role in securing slider

bottom to slider-arch monolith. If needed,

replace these pins with screws (part no.

532979QF) available as spare parts.

Tighten the above screws to 10 Nm.

IMPORTANT: screw and pin threading is

treated to ensure hydraulic seal. Never

reuse screws and pins which have been

removed.

Assembling the brake caliper onto the slider

is a very delicate operation that should be

carried out with extreme care.

Improper assembly might overstress the

caliper supports which might break.

When installing the disc brake system, be

sure to properly follow the instructions given

by the manufacturer.

INSTALLATION

Installing the fork on a bicycle is a very

delicate operation that should be carried

out with extreme care. The installation should

always be checked by one of our Technical

Service Centers.

WARNING: Steer tube/headset

mounting and adjustment must be

carried out in compliance with the headset

manufacturer’s instructions. Improper in-

stallation may jeopardize the safety of the

rider.

To replace it, contact one of our Technical

Service Centers with the required tools.

WARNING: In case of improper

installation of the steer tube into the

crown, the rider might lose control of his/

her bicycle, thus jeopardizing his/her safety.

FRONT WHEEL ASSEMBLY

IMPORTANT: fixing the front wheel prop-

erly as specified in the instructions given

below is essential for the proper operation

of this fork and all related devices, and

therefore for safe riding. You are advised to

follow these instructions closely.

Slacken the lock nut of the quick release

lever so the hub will fit between the fork

sliders.

Make sure the quick release bushings (A)

are centered to the recesses in the sliders.

Lock the quick release lever (B) and make

sure the bushings (A) are properly seated

in the sliders.

Fit bolt end (C) in suitable slider groove and

tighten the screw (D) to specified torque.

WARNING: These sliders are spe-

cifically designed to fit this type of

hub. Do not use any hub design other than

that specified here, as this would not ensure

proper fastening of the wheel and may lead

to breakdown of the assembly components.

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ADJUSTMENT

SPRING PRELOAD

Spring preload determines COMPRESSION

damping and is adjusted by turning the

adjustment knob (2) on the top of the fork

legs. From the factory the fork is set at

minimum preload, i.e. the adjustment knob

completely unscrewed counterclockwise.

However, springs are slightly preloaded to

counteract static loads. By turning the ad-

justment knob clockwise, the preload is

increased up to the maximum value equal

to 15 mm spring preload. This adjustment is

essential in order to have the right fork

response for the rider’s weight and riding

style.

REBOUND ADJUSTMENT VIA

INNER PUMPING ROD

(only right leg)

The adjuster controlling REBOUND damp-

ing adjustment is accommodated inside

pumping rod (14) inside each fork leg.

To access the adjuster, unscrew the top cap

(5) and push the stanchions fully down (see

section DISASSEMBLY, Fig. 1).

Fit the supplied hexagon rod (C) into the

stanchion tube and into the adjuster inner

hole. Rotate the adjuster clockwise for harder

damping, counterclockwise to soften it.

Refit the cap (5) and tighten it to the

specified torque (see section REASSEMBLY,

Fig. 26).

IMPORTANT: Do not remove the springs

or this will alter the amount of oil inside the

fork legs.

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Jumper

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▲

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

DISASSEMBLY

GENERAL

– The reference numbers given in this section relate to the components shown in the fork exploded view.

– Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence.

Locate the part you need to remove in the diagram, then look at the arrows to determine which other parts you need to remove first.

DISASSEMBLY DIAGRAM

FORK LEG OIL CHANGE

CHANGING PUMPING

ELEMENT SEALS

SPRING FIG. 2

DUST SEAL FIG. 5

STOP RING. 6

OIL SEAL FIG. 7

PUMPING ROD FIG. 11

REBOUND SPRING FIG. 11

VALVE ASSEMBLY CHANGE

(only right leg)

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 10

CROWN AND STANCHIONS

ASSEMBLY FIG. 4

SPRING CHANGE

FOOT NUT FIG. 3

STOP RING FIG. 12

UPPER WASHER FIG. 8

PILOT BUSHING FIG. 9

VALVE ASSEMBLY FIG. 12

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SPRING CHANGE

FIG. 1

Unscrew the caps (5) with a 21 mm socket

wrench.

Remove the caps complete with O-ring (6)

from the stanchions.

FIG. 2

Push the stanchions into the sliders and

remove the lower washer (11) and the

spring (34) from each fork leg.

Drain all oil from the fork legs.

WARNING: Remember to always

recycle any used oil.

To change the fork leg oil follow the proce-

dure as described in section “REASSEM-

BLY” from Fig. 24 to Fig. 26.

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 3

Remove foot nuts (29) with a socket

wrench.

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FIG. 4

Withdraw the crown and stanchions as-

sembly (1) from the sliders (30).

FIG. 5

Remove the dust seal (19) from the top of

the sliders using a small screwdriver.

FIG. 6

Remove the stop ring (20) from the sliders

by placing the screwdriver bit in one of the

three openings on the stop ring.

IMPORTANT: when removing the stop

ring, make sure not to damage its seat.

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FIG. 7

Fit the slider protector (A) onto the slider

and remove the oil seal (21) with the help

of a large screwdriver.

IMPORTANT: when removing the oil seal,

make sure not to damage its seat. Once

removed the oil seals should not be used

again.

FIG. 8

Remove the upper washer (22) from the

slider.

FIG. 9

Fit the bit of a small screwdriver into upper

edge slot of the pilot bushing (23) and lift

gently. Pull the bushing out of the slider and

make all necessary changes.

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Jumper

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4225 12

1825 14

Dx.

Sx.

(130)

(110)

40 39 35 16

REPLACING PUMPING ELEMENT

SEALS

FIG. 10

Remove the foot buffer (18) and (42)

complete with ring (25) from the pumping

rod ends (14) and (12).

FIG. 11

Withdraw the pumping elements (14) and

(12) and the rebound springs (15) from

the stanchion tube top.

CAUTION: model with a travel of 110

fit two rebound springs (15) for every

pumping element.

Replace the seal ring (13) placed only on

RH fork leg pumping element, if damaged

or worn out.

VALVE ASSEMBLY CHANGE

(only right leg)

FIG. 12

To check that the valve assembly is operat-

ing correctly, it is necessary to work on the

inside of the stanchion tube.

Slip off the stop ring (17) using pointed

pliers.

Pull the valve assembly (16) out of the

stanchion with one finger in the following

order: pocket (40), valve (39) rebound

spring (35) and washer (16).

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