Marzocchi MXR Coil ext. Preload Bedienungsanleitung

MXR

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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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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-rings at pumping element bottom and

adjusting rod damaged.

Replace the O-rings

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

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

FAILURES CAUSES REMEDIES

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

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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.

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.

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REBOUND ADJUSTMENT

(only left leg)

Each fork leg is equipped with an adjuster

screw (C) 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 (C) over its limit.

ADJUSTMENT

SPRING PRELOAD

Spring preload determines COMPRESSION

damping and is adjusted by turning the

adjustment knob (3) 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.

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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

SPRING FIG. 2

STANCHION TUBE CAP FIG. 1

SPRING CHANGE

BOTTOM ADJUSTER FIG. 3

CROWN AND STANCHIONS

ASSEMBLY FIG. 5

DUST SEAL FIG. 6

STOP RING. 7

PILOT BUSHING AND

SEAL ASSEMBLY CHANGE

FOOT NUT FIG. 4

OIL SEAL FIG. 8

UPPER WASHER FIG. 9

PILOT BUSHING FIG. 10

CHANGING PUMPING

ELEMENT SEALS

FOOT BUFFER FIG. 11

PUMPING ROD FIG. 12

REBOUND SPRING FIG. 12

PUMPING ELEMENT INNER O-RING

FIG. 13

VALVE ASSEMBLY CHANGE

(only left leg)

STOP RING FIG. 14

VALVE ASSEMBLY FIG. 14

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SPRING CHANGE

FIG. 1

Unscrew the caps (4) with a 21 mm socket

wrench.

Remove the caps complete with O-ring (5)

from the stanchions.

FIG. 2

Push the stanchions into the sliders and

remove the lower washer (11) and the

spring (30) 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. 28 to Fig. 30.

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 assem-

bly (28) from the slider.

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FIG. 4

Remove foot nuts (26) and (29) with a

socket wrench.

FIG. 5

Withdraw the crown and stanchions as-

sembly (1) from the sliders.

FIG. 6

Remove the dust seal (19) from the top of

the sliders using a small screwdriver.

Sx.

Dx.

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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.

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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 buffer (18) and (44)

complete with ring (25) from the pumping

rod ends (14) and (12).

1825 14

4425 12

Dx.

Sx.

FIG. 12

Withdraw the pumping elements (14) and

(12) and the rebound springs (15) from

the stanchion tube top.

CAUTION: model with a travel of 80 fit

two rebound springs (15) for every pump-

ing element.

Replace the seal ring (13) placed only on

LH fork leg pumping element, if damaged

or worn out.

15 14

(100)

(80)

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FIG. 13 (only left leg)

Remove the stop ring (33) 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 (27)

if damaged.

VALVE ASSEMBLY CHANGE

(only left leg)

FIG. 14

To check that the valve assembly is operat-

ing correctly, it is necessary to work on the

inside of the left stanchion tube.

Slip off the stop ring (17) using pointed

pliers.

Pull the valve assembly out of the stanchion

with one finger in the following order:

covering (42), valve (41) rebound spring

(31) and washer (16).

42 41 31 16

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