Marzocchi X-Fly 80 Bedienungsanleitung

X-FLY

(80)

TRAVEL 80

100

130

175

L.MAX=461 L.L.=451 L.MIN=371

396

Ø30

9.2

248.5

±2

-0.1

+0.1

Ø30

+0.05

GENERAL

• Special air/oil damped cross-country fork: each leg uses pressu-

rized air blown through a special valve on stanchion caps as

damping medium.

• The right leg rebound is damped by a hydraulic cartridge.

• Rebounddampingadjustmentcontrolledviaexternaltoprightleg

adjuster.

• StanchionsfittedintolowerCrownbycryofittechnique.Fulllength

bushings guarantee superior rigidity.

• Slidersandarch are anintegralassembly for reducedweightand

improved rigidity.

• Partssubjectedtofrictionarecooledandlubricatedbyaspecially

formulated oil.

Steer tube: EASTON aluminum steer tube available for 1 1/8”

diameter, threadless.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Cast magnesium alloy.

Stanchions: anodized aluminum with variable section.

Sliders: Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

Slider bushing: Full length guide bushings composed of a copper

base and impregnated with an anti-friction coating.

Seals: Computer designed oil seals guarantee the highest quality

seals available.

Oil: Speciallyformulated oil which eliminates foamingand viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil: type EBH 16 - SAE 7.5.

– right leg 110 cc,

– left leg 85 cc.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

X-FLY

(100)

TRAVEL 100

100

130

175

L.MAX=481 L.L.=471 L.MIN=371

416.5

Ø30

9.2

248

±2

+0.5

+0.1

Ø30

+0.05

-0.1

GENERAL

• Special air/oil damped cross-country fork: each leg uses pressu-

rized air blown through a special valve on stanchion caps as

damping medium.

• The right leg rebound is damped by a hydraulic cartridge.

• Rebounddampingadjustmentcontrolledviaexternaltoprightleg

adjuster.

• StanchionsfittedintolowerCrownbycryofittechnique.Fulllength

bushings guarantee superior rigidity.

• Slidersandarch are anintegralassembly for reducedweightand

improved rigidity.

• Partssubjectedtofrictionarecooledandlubricatedbyaspecially

formulated oil.

Steer tube: EASTON aluminum steer tube available for 1 1/8”

diameter, threadless.

Crown: Forged and CNC-machined BAM

❊

aluminum alloy.

Arch: Cast magnesium alloy.

Stanchions: anodized aluminum with variable section.

Sliders: Forged and CNC-machined BAM

❊

aluminum alloy. Left

slider comes with supports for disc brake caliper.

Slider bushing: Full length guide bushings composed of a copper

base and impregnated with an anti-friction coating.

Seals: Computer designed oil seals guarantee the highest quality

seals available.

Oil: Speciallyformulated oil which eliminates foamingand viscosity

breakdown while providing complete stiction-free performance.

Fork leg oil: type EBH 16 - SAE 7.5.

– right leg 95 cc,

– left leg 115 cc.

❊

BAM: Bomber Aerospace Material.

Special alloy developed from aerospace material.

X-FLY

INSTRUCTIONS

GENERAL RULES

1. Where specified, assemble and disas-

semble the shock absorption system

usingtheMARZOCCHI specialtoolsonly.

2. On reassembling the suspension sys-

tem, always use new seals.

3. Clean all metal parts with a special,

preferablybiodegradablesolvent,such

astrichloroethaneortrichloroethylene.

4. Beforereassembling,lubricateallparts

in contact with each other using sili-

conefatsprayoraspecificoilforseals.

5. Alwaysgreasethelipsealringsbefore

reassembling.

6. Use wrenches with metric size only.

Wrenches with inch size might dam-

age the fastening devices even when

theirsizeissimilartothatofthewrenches

in metric size.

X-FLY

FAILURES, CAUSES AND REMEDIES

Thisparagraphreportssomefailuresthatmayoccurwhenusingthefork.Italsoindicatespossiblecausesandsuggestsaremedy.Always

refer to this table before doing any repair work.

FAILURES CAUSES REMEDIES

Oil leaking through the bottom of slider O-ringonthepumpingrodoroncartridge

securing nut bottom damaged Replace the O-ring

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. Cleantheoilsealseatandreplaceoilseal

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 Dirt inside fork legs Clean carefully and change oil

Adjuster position does not affect fork op-

eration Dirt inside legs Clean carefully and change oil

X-FLY

RECOMMENDATIONS FOR

MAINTENANCE

MARZOCCHI forksare based on advanced

technology,supportedbyyear-longexpe-

rience in the field of professional moun-

tain biking. In order to achieve best re-

sults, we recommend to check and clean

the area below the dust seal and the

stanchion tube after each use and lubri-

cate with silicone oil.

Ingeneral, MARZOCCHI forkscan offer top

performance from the start. However, in

some cases a short running-in period is

required (5-10 hours) for inner adjust-

ments. This running-in period will make

fork life longer and ensure fork top per-

formance over time.

IMPORTANT: change oil at least every

100workinghoursandcheckpressure 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 head-

set manufacturer’s instructions. Improper

installation may jeopardize the safety of

the rider.

Toreplaceit,contactoneofourTechnical

Service Centers with the required tools.

WARNING: In case of improper

installationofthe steer tubeintothe

crown, the rider might lose control of his/

her bicycle, thus jeopardizing his/her

safety.

DISC BRAKE SYSTEM ASSEMBLY

WARNING: If a disc brake sys-

tem is installed, it is absolutely for-

bidden to loosen and remove original

brake supports fixing pins. In fact, apart

from retaining Cantilever or V-brake le-

vers, they also play an important role in

securingsliderbottomtoslider-archmono-

lith. If needed, replace these pins with

screws (part no. 532979QF) available

as spare parts.

Tighten the above screws to 15 Nm.

IMPORTANT: screw and pin threading

is treated to ensure hydraulic seal. Never

reuse screws and pins which 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.

Wheninstallingthe disc brakesystem, be

sure to properly follow the instructions

given by the manufacturer.

X-FLY

ADJUSTMENTS

FORK LEG PRESSURIZATION

Blow pressurized air through the valves to

set COMPRESSION damping. To change

the pressure inside the fork legs, remove

the protection cap (2) and depressurize

each leg by pushing lightly on valve pin

with a bit. Fully tighten adapter fitting (D),

suppliedwiththefork,onMARZOCCHI pump

(C).Screwfittingend–withO-ring(D1)on

valve, and pressurize until the required

value is reached. Unscrew the fitting/

pump assembly and refit the cap (2).

IMPORTANT: inflate using special

MARZOCCHI pump with pressure gauge.

Useofimpropertoolsorotherprocedures

than specified ones might lead to im-

proper inflating.

NOTE: in case of air leakages when

adapterfitting(D) isfitted, ensure that the

O-ring (D1) is not damaged.

REBOUND ADJUSTMENT

The right fork leg is equipped with an

adjuster screw (A) for REBOUND damp-

ing. Turning this adjuster clockwise into

the cartridge rod, changes the hydraulic

setting of the inner valves. In short, the

amount of adjustment applied on the pis-

ton in the fluid determines the rate of

damping.

To adjust, always start from the minimum

damping setting, i.e. unscrew completely

counterclockwise. About 8 turns - abt. 4

mm of the adjustment - are possible.

X-FLY

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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 OIL CHANGE

STANCHION TUBE CAP FIG. 1/2

AIR VALVE CHANGE

FIG. 13

FOOT NUT FIG. 4

PILOT BUSHING AND SEAL ASSEMBLY CHANGE

CARWON AND STANCHIONS ASSEMBLY FIG. 7

DUST SEAL FIG. 8

STOP RING FIG. 9

OIL SEAL FIG. 10

UPPER WASHER FIG. 11

PILOT BUSHING FIG. 12

PUMPING ROD, REBOUND SPRING

AND WASHER FIG. 6

HYDRAULIC CARTRIDGE, REBOUND

SPRING AND WASHER FIG. 5

PUMPING ROD CHANGE

(left leg)

HYDRAULIC CARTRIDGE CHANGE

(right leg)

X-FLY

118

FIG. 1

Depressurize each fork leg (see section

ADJUSTMENT).

Unscrew the caps (6) and (7) with a 21

mm socket wrench.

Removethe cap (6) complete with O-ring

(5) from the left stanchion tube.

FIG. 2 (only right leg)

Lock the check nut (26) and remove the

cap (7) from hydraulic cartridge end

(12).

FIG. 3

Push the stanchions (1) into the sliders

(18) and let all the oil drain out from the

fork legs.

Pump the stanchions several times to help

oil drain off.

WARNING:Remembertoalways

recycle any used oil.

To change the fork leg oil follow the

procedure as described in section

“REASSEMBLY” from Fig. 22 to Fig. 24.

X-FLY

HYDRAULIC CARTRIDGE CHANGE

AND PUMPING ROD CHANGE

FIG. 4

Turn the fork leg upside-down and un-

screwthefootnuts(20) bytheuseofa15

mmsocket wrench completewith O-Rings

(19).

FIG. 5 (only right leg)

Pullthehydrauliccartridge(12)complete

with rebound spring (9) and foot washer

(23, see exploded view) out of the R.H.

stanchion tube.

Replace the whole hydraulic cartridge.

FIG. 6 (only left leg)

A pumping rod (8) complete with re-

bound spring (9) and foot washer (23,

see exploded view) is fitted into the L.H.

leg, inside the stanchion.

Withdraw the above parts from the tube

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