Marzocchi MXR Air Bedienungsanleitung

MXR

Air

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.

MXR

Air

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 bottom of slider O-rings at pumping element bottom and

adjusting rod damaged.

Replace the O-rings

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

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

The fork reaches its end of stroke easily Valve at the bottom of the stanchion

damaged

Change

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

Fork rebounds too fast in any adjuster

position

Dirt inside fork legs Clean carefully and change oil

Adjuster position does not affect fork

operation

1. Dirt inside legs

2. O-ring into pumping element damaged

1. Clean carefully and change oil

2. Replace O-ring

MXR

Air

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, brake supports fixing

pins for cantilever or linear pull brakes can

be replaced 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.

MXR

Air

ADJUSTMENTS

FORK LEG PRESSURIZATION

Blow pressurized air through the valves (5)

on the stanchion caps to set COMPRES-

SION damping. To change the pressure

value, remove the protection cap (2) and

depressurize each leg. Fully tighten the

pump connection (C) on cap valve (5) or

pressurize until the required value is reached.

Unscrew the connection and refit the cap

(2). This adjustment is essential in order to

have the right fork response for the rider’s

weight and riding style.

The fork is pre-loaded at the factory to a

standard value of 3 bar.

REBOUND ADJUSTMENT

Each fork leg is equipped with an adjuster

screw (D) for REBOUND damping at slider

bottom.

To adjust, always start from the minimum

damping setting, i.e. with the screw fully

turned counterclockwise. Each adjusting

position can be identified by a click.

IMPORTANT: do not force the adjuster

knob (D) over its limit.

MXR

Air

▲

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

CROWN AND STANCHIONS

ASSEMBLY CHANGE

FOOT BUFFER FIG. 11

PUMPING ROD FIG. 12

STOP RING. 7

FORK OIL CHANGE

PUMPING ELEMENT INNER O-RING

FIG. 13

STOP RING FIG. 14

VALVE ASSEMBLY FIG. 14

DUST SEAL FIG. 6

STANCHION TUBE CAP FIG. 1

REBOUND SPRING FIG. 12

BOTTOM ADJUSTER FIG. 3

VALVE ASSEMBLY CHANGE

FOOT NUT FIG. 4

CROWN AND STANCHIONS

ASSEMBLY FIG. 5

PUMPING ROD CHANGE

OIL SEAL FIG. 8

UPPER WASHER FIG. 9

PILOT BUSHING FIG. 10

MXR

Air

111

FIG. 1

Depressurize each fork leg (see section

ADJUSTMENT).

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 (1) into the sliders (11)

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

Pump the stanchions several times to help

oil drain off.

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. 27 to Fig. 29.

PILOT BUSHING AND SEAL

ASSEMBLY CHANGE

FIG. 3 (only left leg)

Turn fork legs upside down and press

adjuster retainer (28) with a small screw-

driver to release it.

Remove adjuster assembly (28) from the

left slider.

MXR

Air

26 7

Sx.

Dx.

FIG. 4

Remove foot nuts (26) and (7) by the use

of a 15 mm socket wrench.

FIG. 5

Withdraw the crown and stanchions as-

sembly (1) from the sliders (11).

FIG. 6

Remove the dust seal (19) from the top of

the sliders using a small screwdriver.

MXR

Air

FIG. 7

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.

FIG. 8

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. 9

Remove the upper washer (22) from the

slider.

MXR

Air

1825 14

3225 12

Dx.

Sx.

FIG. 10

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.

REPLACING PUMPING ELEMENT

SEALS

FIG. 11

Remove the foot buffers (18)and (32)

complete with ring (25) from the pumping

rod ends (14) and (12).

12 14

FIG. 12

Withdraw the pumping elements (14) and

(12) and the rebound spring (15) from the

stanchion tube top. Replace the seal ring

(13) if damaged or worn out (fitted to LH

pumping rod only).

MXR

Air

1634 3033

VALVE ASSEMBLY CHANGE

FIG. 14 (only left leg)

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 out of the tube with

one finger in the same sequence as in the

figure: covering (33), valve (34) rebound

spring (30) and washer (16).

FIG. 13 (only left leg)

Remove the stop ring (4) from pumping

element bottom (14) with a small flat screw-

driver.

Mark stop ring seat into inner rod for proper

fitting.

Use the same screwdriver to remove the

ring (A) and screw inner rod until adjuster

threaded end is disengaged from pumping

element.

Remove inner rod and replace O-ring (3) if

damaged.

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