Marzocchi Jr. T QR20 Bedienungsanleitung

Jr. T

QR20

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system us-

ing M

ARZOCCHI

special tools only.

2. On reassembling the suspension system,

always use new seals.

3. If two screws are close one to the other,

always tighten using a 1-2-1 sequence.

In short, screw the first screw just up to the

point it is well tightened, then tighten the

second screw and then go back to the

first one and screw it tighter.

4. Clean all metal parts with a special,

preferably biodegradable solvent, such

as trichloroethane or trichloroethylene.

5. Before reassembling, lubricate all parts

in contact with each other using silicone

fat spray or a specific oil for oil seals.

6. Always grease the conic seal rings be-

fore reassembling.

7. 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.

Jr. T

QR20

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.

Excessive oil build up on stanchions 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on oil seal

1. Replace oil seal

2. Replace stanchion tube, oil seal and dust

seal

3. Clean the oil seal seat and replace oil

seal

FAILURES CAUSES REMEDIES

Oil leaking through the bottom of slider O-rings on the pumping rod bottom dam-

aged

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

stanchion tube

Raise dust seal and lubricate stanchion

tube, dust seal and oil seal

Excessive play of stanchions into the sliders Main slider bushings are worn Replace main slider bushings

Adjuster position does not affect fork opera-

tion

Dirt inside legs Clean carefully and change oil

Jr. T

QR20

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.

Jr. T

QR20

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: “A-Head Set” head-

set/Steering tube mounting and ad-

justment must be carried out in compliance

with the headset manufacturer’s instruc-

tions. Improper installation may jeopardize

the safety of the rider.

After any installation always check for the

proper torque of screws fastening stan-

chion tube onto lower crown and on upper

crown.

Have steer tube replaced at an authorized

Technical Service Centers only.

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.

MOUNTING THE FORK ON THE

FRAME

FIG. A

Remove the upper crown (1) from steer

tube and fork legs by loosening the 3

fastening bolts (11).

FIG. B

Assemble the fork to the frame complete

with headset. Fit the upper crown (1) into

the upper stanchions and the steer tube.

Jr. T

QR20

2828

FIG. C

The stanchions edge (28) must be aligned

with or slightly lower than the upper crown

(1).

If fork legs overprotrude, fit some spacers

(D) to the plate close to the steer tube.

FIG. D

Fit the handlebar support and the “A-Head

Set” plug over the upper crown (1) and

then adjust the steering.

Now finally tighten the 3 bolts (11) on the

upper crown to 9 Nm.

WARNING: Loosen the 3 screws

(11) on the upper crown before

adjusting the steering. Tighten the above

bolts to the specified torque when finished.

FIG. E

If the crown (13) position with respect to

the stanchions (28) has been changed for

any reason, adjust the original distance.

– Distance H between crown and tyre

edge (when inflated) should not be lower

than total travel (170 mm or 150 mm)

+ 3 mm.

WARNING: If lower Crown is im-

properly matched with stanchions, it

may touch the tyre and cause severe inju-

ries to the rider.

Jr. T

QR20

Nm11

Nm6

FIG. F

Tighten the 4 stanchions fastening screws

(15) onto the crown to 11 Nm.

WARNING: do not overtighten the screws

holding the stanchions to the crown as this

may distort the stanchions and weaken the

whole structure.

After any installation always check for the

following.

Proper torque of bolts fastening stanchion

tube onto lower crown (11 Nm) and upper

crown (see FIG. D).

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.

DISC BRAKE SYSTEM ASSEMBLY

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.

Jr. T

QR20

ADJUSTMENT

SPRING PRELOAD

Spring preload can be adjusted by turning

the 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 un-

screwed counterclockwise. However,

springs are slightly preloaded to counteract

static loads during COMPRESSION. By

turning the adjuster 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 DAMPING ADJUSTMENT

The adjuster controlling REBOUND damp-

ing adjustment is accommodated inside

cartridge rod (27) inside each fork leg.

To access the adjuster, unscrew the top caps,

push the stanchions fully down and take the

washer and preload sleeve out (see section

DISASSEMBLY, Fig. 1 and 2)

WARNING: Do not remove the

springs or this will alter the amount of

oil inside the fork legs.

Insert supplied hexagonal rod (C) in the

stanchion tube and rod edge into adjuster

hexagonal hole.

Rotate the adjuster clockwise for harder

damping, counterclockwise to soften it.

Refit the preload sleeve, washer and cap.

Tighten cap to the specified torque (see

section REASSEMBLY, Fig. 24 and 25).

Jr. T

QR20

▲

DISASSEMBLY

GENERAL

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

– Operations refer to the fork legs already removed from the upper crown and from the crown.

– 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

SPRING FIG. 2

FOOT BUFFER FIG. 10

CARTRIDGE ROD FIG. 10

FOOT NUT FIG. 3

STANCHION TUBE CAP FIG. 1

DUST SEAL FIG. 5

STOP RING FIG. 6

OIL SEAL FIG. 7

CARTRIDGE ROD CHANGE

VALVE ASSEMBLY CHANGE

STOP RING FIG. 11

VALVE ASSEMBLY FIG. 11

GUIDE BUSHING AND SEAL

ASSEMBLY CHANGE

SPRING CHANGE

REBOUND SPRING FIG. 10

STANCHION TUBE FIG. 4

UPPER WASHER FIG. 8

GUIDE BUSHING FIG. 9

Jr. T

QR20

SPRING CHANGE

FIG. 1

Place the stanchion tube (28) in a vice. Be

sure not to damage or squeeze stanchion in

the process. Unscrew the plugs (5) with a

26 mm hexagon wrench.

Remove the plugs complete with the O-ring

(6) from the stanchions.

FIG. 2

Push the stanchion tube into the slider and

remove the upper washer (9), the preload

sleeve (16), the spring (17), the retaining

ring cap (34) and the spring (37).

Make all necessary changes.

GUIDE BUSHING AND

SEAL ASSEMBLY CHANGE

FIG. 3

Let all the oil drain out.

WARNING: Remember to always

recycle any used oil.

To change the fork leg oil follow the proce-

dure as described in section “REASSEMBLY”

from Fig. 22 to Fig. 25.

Turn the fork leg upside-down and unscrew

the foot nut (39) by the use of a 15 mm

socket wrench.

37 34

Jr. T

QR20

GUIDE BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 4

Pull the stanchion tube (28) completely out

of the slider (24).

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.

Andere Handbücher für Jr. T QR20

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