Marzocchi MARATHON Bedienungsanleitung

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.

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 through the top of the slider 1. Oil seal is worn out

2. Stanchion tube is scored

3. Excessive dirt on slider 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 and dust seal

Oil leaking through the bottom of slider O-ring seal on the cartridge nut is damaged Replace the O-ring

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

Pressure drop Cap valve damaged Replace cap and/or valve

Excessive play of stanchions in the sliders Pilot bushings worn out Replace bushings

Fork rebounds too fast in any adjuster

position

1.Dirt inside fork legs

2. RH stanchion cartridge is damaged

3. LH stanchion cartridge is faulty

1.Clean carefully and change oil

2. Replace RH stanchion cartridge

3. Check LH stanchion cartridge

Adjuster position does not affect fork

operation

1.Dirt inside legs

2. Check cartridges operation

1.Clean carefully and change oil

2. Replace and/or overhaul cartridges

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 and check pressure at

least every 10 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 on Marathon 29" forks

featuring sliders glued to the arch, it is

absolutely forbidden to remove the original

bolts (ref. B). In case of a Marathon S fork

it is allowed since arch-slider monolith is

molded.

For Marathon 29”, apart from retaining

cantilever or linear pull brakes, they also

secure the sliders legs to the slider monolith.

If needed, the brake boss bolts can be

replaced with buttonhead bolts (ref. A,

part #532979QF).

Tighten the above-mentioned bolts to 10

Nm.

IMPORTANT: the bolt threads (ref. A)

are treated to ensure a hydraulic seal.

Never reuse the bolts once they 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.

D32

1 3

ADJUSTMENTS

FORK LEG PRESSURIZATION

Pump air through the valves to set COM-

PRESSION damping, as indicated in the

figure. To change the pressure inside the

fork legs, remove the protection cap (32)

(LH fork leg), remove plug (21), turn knob

(28) until you can see the valve under it (RH

fork leg). Depressurize each leg by pushing

lightly on valve pin. Fully tighten adapter

fitting (D) supplied with the fork, on a

ARZOCCHI

pump (C). Screw fitting end –

with O-ring (D1) on valve, and pressurize

until the required value is reached. Un-

screw the fitting/pump assembly and refit

the cap (32).

IMPORTANT: inflate using the special

ARZOCCHI

pump with the proper pressure

gauge. Use of improper tools or other

procedures than specified ones might lead

to improper inflating.

NOTE: in case of air leakages when adapter

fitting (D) is fitted, ensure that the O-ring

(D1) is not damaged.

REBOUND ADJUSTMENT

(r.h. fork leg)

The right fork leg is equipped with an

Extension Control Cartridge adjuster knob

(28) for REBOUND damping up to max.

rebound damping - “Lock Out”. Turning this

adjuster into the cartridge rod, changes the

hydraulic setting of the inner valves.

You can have three adjustments:

Pos. 1: “Lock Out”

Turn the knob completely counter-clockwise

to obtain full ECC lockdown (maximum

rebound damping) for steep climbs and

road riding.

Pos. 2: “Intermediate rebound

damping”

Turn the knob clockwise until hearing the

first click. This mediuam position offers slow

rebound damping for fast starts and rough

climbs.

Pos. 3: “Minimum rebound

damping”

Turn the knob completely clockwise until

hearing the last click. In this position the fork

will have fast rebound damping for

downhilling.

IMPORTANT: do not force the adjuster

knob (28) past its limit.

NEGATIVE AIR CARTRIDGE ADJUST-

MENT (LH fork leg –valve is

located in the center of the cap)

Pump air into the valve, as indicated, to set

COMPRESSION damping. To change the

pressure inside the fork legs, remove the

protection cap (32) (LH fork leg) and

depressurize the leg by pushing lightly on

valve pin. Fully tighten adapter fitting (D),

supplied with the fork, on M

ARZOCCHI

pump

(C). Screw fitting end –with O-ring (D1) on

valve, and pressurize until the required

value is reached. The higher the pressure in

the LH cartridge, the more sensitive the fork

will be and vice versa.

Unscrew the fitting/pump assembly and

refit the cap (32).

IMPORTANT: inflate using the special

ARZOCCHI

pump with the proper

pressure gauge. Use of improper tools or

other procedures than specified ones

might lead to improper inflating.

NOTE: in case of air leakage when adapter

fitting (D) is installed, be sure that the O-

ring (D1) is not damaged.

1 3

▲

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 OIL CHANGE

STANCHION TUBE CAP FIG. 1/2/3/4

AIR VALVE CHANGE

FIG. 15

FOOT NUT FIG. 6

PILOT BUSHING AND SEAL ASSEMBLY CHANGE

CARWON AND STANCHIONS ASSEMBLY FIG. 9

DUST SEAL FIG. 10

STOP RING FIG. 11

OIL SEAL FIG. 12

UPPER WASHER FIG. 13

PILOT BUSHING FIG. 14

AIR-OPERATED CARTRIDGE FIG. 8

HYDRAULIC CARTRIDGE FIG. 7

AIR-OPERATED CARTRIDGE

CHANGE (left leg)

HYDRAULIC CARTRIDGE CHANGE

(right leg)

AIR-OPERATED CARTRIDGE

OVERHAUL FIG 16/17/18

29 28 32

27 25

REMOVING UPPER CAP

FIG. 1

(r.h. fork leg)

Undo screw (29) with an Allen wrench and

remove knob (28).

(l.h. fork leg)

Completely undo knob (32).

Depressurize each fork leg (see section

ADJUSTMENT).

FIG. 2 (only right leg)

Remove the RH cartridge circlip (27) with

a small screwdriver.

Remove and keep the pin (26) and counter

spring (25).

WARNING: never use the fork with-

out this component otherwise the

hydraulic cartridge fitted to the slider bot-

tom might slide out from the top cap and

release the arch-slider monolith.

FIG. 3

Unscrew the caps (30) and (33) complete

with O-ring (24) with a 21-mm socket

wrench.

Remove the cap (30) from the right stan-

chion and from the hydraulic cartridge rod

(5).

23 3

FIG. 4 (only left leg)

Lock the rod (16) and remove the cap (33)

from hydraulic cartridge end (22).

If this operation proves difficult, vice the rod

with jaws (E) (see Fig. 28).

FIG. 5

Push the stanchions (23) into the sliders (3)

and let all the oil drain out from the fork legs.

Pump the stanchions several times to help

oil drain off.

WARNING: dispose of exhausted

oil in compliance with current laws.

To change the fork leg oil follow the proce-

dure as described in section “REASSEMBLY”

from Fig. 29 to Fig. 33.

REMOVING CARTRIDGES

FIG. 6

Turn the fork leg upside-down and unscrew

the foot nuts (2) by the use of a 15 mm

socket wrench complete with O-Rings (1).

FIG. 7 (only right leg)

Pull the hydraulic cartridge (5) out of the

R.H. stanchion tube.

Replace the whole hydraulic cartridge.

FIG. 8 (only left leg)

Pull the air-operated cartridge (22) out of

the L.H. stanchion tube.

Replace the whole cartridge or overhaul as

described in next paragraph.

FIG. 9

Withdraw the crown and stanchions as-

sembly (23) from the sliders (3).

10 9

REMOVING GUIDE BUSHING

AND SEAL ASSEMBLY

FIG. 10

Remove the dust seal (10) from the top of

the sliders using a small screwdriver.

FIG. 11

Remove the stop ring (9) 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 slider inner

seat.

FIG. 12

Fit the slider protector (A) onto the slider

and remove the oil seal (8) with the help of

a large screwdriver.

IMPORTANT: when removing the oil seal,

make sure not to damage slider inner seat.

Once removed the oil seals should not be

used again.

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