Marzocchi EXR Coil Bedienungsanleitung

EXR

Coil

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.

EXR

Coil

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.

Oil leaking through the bottom of slider O-ring on pumping rod nut damaged Replace the O-ring

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

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

FAILURES CAUSES REMEDIES

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

EXR

Coil

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.

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.

DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake system

is installed, it is possible to replace

original brake supports fixing pins with

screws (part no. 532979QF) available as

spare parts.

Tighten the above screws to 10 Nm.

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.

EXR

Coil

ADJUSTMENT

SPRING PRELOAD

Take off the rubber protection (2).

To change preload, turn the screw (4)

inside cap (5) using a 4 mm Allen wrench.

Turn out the screw (4) completely, then

tighten it until it touches the upper washer

(7). From this starting position, which cor-

responds to “0” preload, turn in as many

turns as the preload you want. Each turn

corresponds to 1.25 mm.

When supplied, the fork is set to the mini-

mum preload. However, spring is slightly

preloaded to counteract static loads. By

turning the adjustment screw clockwise, the

preload is increased up to the maximum

value equal to 15 mm’s of spring preload.

This adjustment is essential in order to have

the right fork response for the rider’s weight

and riding style.

EXR

Coil

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

PUMPING ROD CHANGE

FOOT NUT FIG. 3

SPRING FIG. 2

DUST SEAL FIG. 5

STOP RING. 6

OIL SEAL FIG. 7

PUMPING ROD FIG. 8

REBOUND SPRING FIG. 8

VALVE ASSEMBLY CHANGE

SEAL ASSEMBLY CHANGE

STANCHION TUBE CAP FIG. 1

CROWN AND STANCHIONS ASSEM-

BLY FIG. 4

SPRING CHANGE

STOP RING FIG. 9

VALVE ASSEMBLY FIG. 9

EXR

Coil

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 (7) and the

spring (8) 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. 17 to Fig. 19.

SEAL ASSEMBLY CHANGE

FIG. 3

Turn the fork leg upside-down and unscrew

the foot nuts (20) complete with O-ring

(19) by the use of a 15 mm socket wrench.

EXR

Coil

FIG. 4

Withdraw the crown and stanchions as-

sembly (1) from the sliders (18).

FIG. 5

Remove the dust seal (15) from the top of

the sliders using a small screwdriver.

FIG. 6

Remove the stop ring (16) 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.

EXR

Coil

FIG. 7

Fit the slider protector (A) onto the slider

and remove the oil seal (17) 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

Withdraw the pumping elements (10) and

the rebound spring (11) from the stanchion

tube top. Replace the seal ring (9) if dam-

aged or worn out.

VALVE ASSEMBLY CHANGE

FIG. 9

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 (22) using pointed

pliers.

Pull the valve assembly out of the tube with

one finger in the same sequence as in the

figure: covering (14), valve (13) and

washer (12).

14 13 12

EXR

Coil

REASSEMBLY

CAUTION: before reassembling, all metal

components should be washed carefully

with inflammable, preferably biodegrad-

able, solvent and dried with compressed

air.

SEAL REASSEMBLY

FIG. 10

Lubricate the oil seal (17) and place it onto

the seal press (B) with the hollow side

toward the slider.

Press the oil seal until it touches the lower

washer by using the above seal press.

FIG. 11

Insert the stop ring (16) into the slider

making sure it is properly seated into place.

Use buffer (B) to properly seat the ring into

the slider.

FIG. 12

Lubricate the dust seals (15) and fit them

into the stanchions from the spring end.

EXR

Coil

VALVE AND PUMPING ROD

ASSEMBLY

FIG. 13

After having overhauled or replaced the

valve unit and after having cleaned the

inside of the tube, reassemble. Assemble

valve components, in correct sequence:

washer (12), valve (13) and covering

(14).

Then fit pumping rod (10) with seal ring (9)

and rebound spring (11) into the valve

assembly.

FIG. 14

Fit this assembly into the stanchion tube and

properly seat the valve assembly (C).

Insert the stop ring (22).

CROWN AND STANCHIONS

ASSEMBLY

FIG. 15

Fit the crown and stanchions assembly (1)

- with the dust seals in place - gently into the

sliders seals.

WARNING: to avoid any dam-

ages to sealing surfaces, keep the

stanchions duly lubricated and squared

into the sliders.

Press the crown and stanchions assembly

fully down and check that threaded ends of

pumping elements (10) are coming out

through the bottom of the sliders.

Check to see that the stanchions slide unre-

stricted by cycling the fork up and down

several times.

The tube should slide freely inside the seal

assembly without any side play. In the event

it is too hard or too soft, repeat the previous

steps described above and check compo-

nents to ensure they are not damaged.

Seat the dust seals (15) on top of the

sliders.

15 15

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