Marzocchi X-Fly 80 Bedienungsanleitung
X-FLY
(80)
TRAVEL 80
100
80
130
175
L.MAX=461 L.L.=451 L.MIN=371
396
Ø30
18
25
9.2
55
248.5
±2
±2
15
20
0
-0.1
+1
0
+0.1
0
+0.1
0
Ø30
+0.05
0
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
80
130
175
L.MAX=481 L.L.=471 L.MIN=371
416.5
Ø30
18
25
9.2
55
248
±2
±2
+0.5
0
+0.1
0
Ø30
+0.05
0
15
20
0
-0.1
+1
0
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
D
D
D1
2
CC
A
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
7
5
118
7
26
12
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
20
19
12
9
8
9
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
top by pushing them from slider bottom.
X-FLY
1
18
13
14
FIG. 7
Withdraw the crown and stanchions as-
sembly (1) from the sliders (18).
FIG. 8
Remove the dust seal (13) from the top of
the sliders using a small screwdriver.
FIG. 9
Removethestopring(14)fromthesliders
byplacingthescrewdriverbitinoneofthe
three openings on the stop ring.
IMPORTANT: when removing the stop
ring, make sure not to damage its seat.
Dieses Handbuch passt für folgende Modelle
1
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