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(110)

GENERAL• The fork is sprung by a mechanical coil system and uses

hydraulic rebound damping for Freeride use.• Rebound damping is controlled by pumping rods fixed to the

bottom of each slider; it can also be adjusted from the inside ofthe stanchions.

• Spring pre-load adjustment controlled via external adjuster onstanchion plugs.

• Stanchions fitted into lower Crown by cryofit technique. Fulllength bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weightand improved rigidity.

• Parts subjected to friction are cooled and lubricated by aspecially formulated oil.

Steer tube: stainless steel available for 1 1/8” diameter, thread-less.Crown: Forged and CNC-machined BAM❊ aluminum alloy.Arch: Cast aluminum alloy.Stanchions: anodized aluminum with variable section.Springs: Constant pitch springs.Sliders: forged and CNC-machined aluminum. Left slider comeswith supports for disc brake caliper.Slider bushing: Full length guide bushings composed of acopper base and impregnated with an anti-friction coating.Seals: Computer designed oil seals guarantee the highest qualityseals available.Oil: Specially formulated oil which eliminates foaming and viscos-ity breakdown while providing complete stiction-free performance.Fork leg oil: 85 cc (each leg), type EBH 16 - SAE 7.5.

❊ BAM: Bomber Aerospace Material.Special alloy developed from aerospace material.

CO

RSA

11

0

100

80

130

175

L.M

AX

=5

12

,9

L.

L.=

48

2,9

L.M

IN=

37

9,9

42

5,9

Ø 30

18

259.2

57

24

8.5

±2

±2

±2+0.1 0

Ø 30+0.05 0

15

20

0-0.1

+1 0

TRAV

EL 1

10

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(130)

GENERAL• The fork is sprung by a mechanical coil system and uses

hydraulic rebound damping for Freeride use.• Rebound damping is controlled by pumping rods fixed to the

bottom of each slider; it can also be adjusted from the inside ofthe stanchions.

• Spring pre-load adjustment controlled via external adjuster onstanchion plugs.

• Stanchions fitted into lower Crown by cryofit technique. Fulllength bushings guarantee superior rigidity.

• Sliders and arch are an integral assembly for reduced weightand improved rigidity.

• Parts subjected to friction are cooled and lubricated by aspecially formulated oil.

Steer tube: stainless steel available for 1 1/8” diameter, thread-less.Crown: Forged and CNC-machined BAM❊ aluminum alloy.Arch: Cast aluminum alloy.Stanchions: anodized aluminum with variable section.Springs: Constant pitch springs.Sliders: forged and CNC-machined aluminum. Left slider comeswith supports for disc brake caliper.Slider bushing: Full length guide bushings composed of acopper base and impregnated with an anti-friction coating.Seals: Computer designed oil seals guarantee the highest qualityseals available.Oil: Specially formulated oil which eliminates foaming and viscos-ity breakdown while providing complete stiction-free performance.Fork leg oil: 90 cc (each leg), type EBH 16 - SAE 7.5.

❊ BAM: Bomber Aerospace Material.Special alloy developed from aerospace material.

CO

RSA

130

100

80

130

175

L.M

AX

=5

12,9

L.L.

=5

02,9

L

.MIN

=379,9

445

,9

Ø 30

18

259.2

57

248.5

±2

±2

±2+0.1 0

Ø 30+0.05 0

15

20

0-0.1

+1 0

TRAV

EL 1

30

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INSTRUCTIONS

GENERAL RULES1. Where specified, assemble and disas-

semble the shock absorption system us-ing the MARZOCCHI special tools only.

2. On reassembling the suspension system,always use new seals.

3. Clean all metal parts with a special,preferably biodegradable solvent, suchas trichloroethane or trichloroethylene.

4. Before reassembling, lubricate all partsin contact with each other using siliconefat spray or a specific oil for seals.

5. Always grease the lip seal rings beforereassembling.

6. Use wrenches with metric size only.Wrenches with inch size might damagethe fastening devices even when theirsize is similar to that of the wrenches inmetric size.

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FAILURES, CAUSES AND REMEDIESThis 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-ring on pumping rod nut damaged Replace the O-ring

Oil leaking though the top of slider 1. Oil seal is worn out2. Stanchion tube is scored3. Excessive dirt on oil seal1. Replace oil seal

2. Replace crown/stanchions assembly,oil seals and dust seals

3. Clean the oil seal seat and replace oilseal

Fork has not been used for some timeand is locked out

Oil seals and dust seals tend to stick tostanchions

Raise dust seal and lubricate stanchiontube, dust seal and oil seal

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

FAILURES CAUSES REMEDIES

Fork rebounds too fast in any adjusterposition

Dirt inside fork legs Clean carefully and change oil

Adjuster position does not affect forkoperation

1. Dirt inside legs2. Pumping element does not work

properly

1. Clean carefully and change oil2. Replace pumping element

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RECOMMENDATIONS FORMAINTENANCEMARZOCCHI forks are based on advancedtechnology, supported by year-long experi-ence in the field of professional mountainbiking. In order to achieve best results, werecommend to check and clean the areabelow the dust seal and the stanchion tubeafter each use and lubricate with siliconeoil.In general, MARZOCCHI forks can offer topperformance from the start. However, insome cases a short running-in period isrequired (5-10 hours) for inner adjustments.This running-in period will make fork lifelonger and ensure fork top performanceover time.

IMPORTANT: change oil at least every100 working hours.

Polished forks should be cleaned withbodywork polish at regular intervals inorder to preserve their original finish.

INSTALLATIONInstalling the fork on a bicycle is a verydelicate operation that should be carriedout with extreme care. The installation shouldalways be checked by one of our TechnicalService Centers.

WARNING: Steer tube/headsetmounting and adjustment must be

carried out in compliance with the headsetmanufacturer’s instructions. Improper in-stallation may jeopardize the safety of therider.To replace it, contact one of our TechnicalService Centers with the required tools.

WARNING: In case of improperinstallation of the steer tube into the

crown, the rider might lose control of his/her bicycle, thus jeopardizing his/her safety.

DISC BRAKE SYSTEM ASSEMBLYWARNING: If a disc brake systemis installed, it is absolutely forbidden

to loosen and remove original brake sup-ports fixing pins. In fact, apart from retain-ing Cantilever or V-brake levers, they alsoplay an important role in securing sliderbottom to slider-arch monolith. If needed,replace these pins with screws (part no.532979QF) available as spare parts.Tighten the above screws to 10 Nm.

IMPORTANT: screw and pin threading istreated to ensure hydraulic seal. Neverreuse screws and pins which have beenremoved.

Assembling the brake caliper onto the slideris a very delicate operation that should becarried out with extreme care.Improper assembly might overstress thecaliper supports which might break.When installing the disc brake system, besure to properly follow the instructions givenby the manufacturer.

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REBOUND ADJUSTMENT VIAINNER PUMPING RODThe adjuster controlling REBOUND damp-ing adjustment is accommodated insidepumping rod (10) inside each fork leg.To access the adjuster, unscrew the top cap(4) and push the stanchions fully down (seesection DISASSEMBLY Fig. 1).Fit the supplied hexagon rod (C) into thestanchion tube and into the adjuster innerhole. Rotate the adjuster clockwise for harderdamping, counterclockwise to soften it.Refit the cap (4) and tighten it to thespecified torque (see section REASSEM-BLY, Fig. 24).

IMPORTANT: Do not remove the springsor this will alter the amount of oil inside thefork legs.

ADJUSTMENTSPRING PRELOADSpring preload determines COMPRESSIONdamping and is adjusted by turning theadjustment knob (3) on the top of the forklegs. From the factory the fork is set atminimum preload, i.e. the adjustment knobcompletely unscrewed counterclockwise.However, springs are slightly preloaded tocounteract static loads. By turning the ad-justment knob clockwise, the preload isincreased up to the maximum value equalto 15 mm spring preload. This adjustment isessential in order to have the right forkresponse for the rider’s weight and ridingstyle.

3

C

10

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DISASSEMBLYGENERAL– 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

PUMPING ROD CHANGE

FOOT NUT FIG. 3

SPRING FIG. 2

DUST SEAL FIG. 5

STOP RING. 6

OIL SEAL FIG. 7

PUMPING ROD FIG. 10

REBOUND SPRING FIG. 10

VALVE ASSEMBLY CHANGE

PILOT BUSHING AND SEALASSEMBLY CHANGE

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 10

CROWN AND STANCHIONSASSEMBLY FIG. 4

SPRING CHANGE

UPPER WASHER FIG. 8STOP RING FIG. 11

PILOT BUSHING FIG. 9VALVE ASSEMBLY FIG. 11

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SPRING CHANGEFIG. 1Unscrew the caps (4) with a 21 mm socketwrench.Remove the caps complete with O-ring (5)from the stanchions.

FIG. 2Push the stanchions into the sliders andremove the lower washer (33) and thespring (8) from each fork leg.Drain all oil from the fork legs.

WARNING: Remember to alwaysrecycle any used oil.

To change the fork leg oil follow the proce-dure as described in section “REASSEM-BLY” from Fig. 22 to Fig. 24.

PILOT BUSHING AND SEALASSEMBLY CHANGEFIG. 3Turn the fork leg upside-down and unscrewthe foot nuts (22) by the use of a 15 mmsocket wrench.

4

5

8

33

22

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FIG. 4Withdraw the crown and stanchions as-sembly (1) from the sliders (20).

FIG. 5Remove the dust seal (15) from the top ofthe sliders using a small screwdriver.

FIG. 6Remove the stop ring (16) from the slidersby placing the screwdriver bit in one of thethree openings on the stop ring.

IMPORTANT: when removing the stopring, make sure not to damage its seat.

1

20

15 16

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FIG. 7Fit the slider protector (A) onto the sliderand remove the oil seal (17) with the helpof a large screwdriver.

IMPORTANT: when removing the oil seal,make sure not to damage its seat. Onceremoved the oil seals should not be usedagain.

FIG. 8Remove the upper washer (18) from theslider.

FIG. 9Fit the bit of a small screwdriver into upperedge slot of the pilot bushing (19) and liftgently. Pull the bushing out of the slider andmake all necessary changes.

17

A

18

19

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PUMPING ROD CHANGEFIG. 10Remove the foot buffer (14) with the o-ring(27) from the pumping rod (10) end.Withdraw the complete pumping rod (10)and the rebound spring (11) from the top.Replace the seal ring (9) if damaged orworn out.

VALVE ASSEMBLY CHANGEFIG. 11To check that the valve assembly is operat-ing correctly, it is necessary to work on theinside of the stanchion tube.Slip off the stop ring (13) using pointedpliers.Pull the valve assembly out of the stanchionwith one finger in the following order:pocket (30), valve (29) and washer (12).

9

11

1427

10

13

122930

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REASSEMBLYCAUTION: before reassembling, all metalcomponents should be washed carefullywith inflammable, preferably biodegrad-able, solvent and dried with compressedair.

PILOT BUSHING AND SEALASSEMBLYFIG. 12Check that no dirt or debris is betweenslider and bushing. Insert the pilot bushing(19) into place so that it adheres to theslider.

FIG. 13Fit the upper washer (18) into the slider sothat it touches the pilot bushing.

FIG. 14Lubricate the oil seal (17) and place it ontothe seal press (B) with the hollow sidetoward the slider.Press the oil seal until it touches the lowerwasher by using the above seal press.

19

18

17

B

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FIG. 15Insert the stop ring (16) into the slidermaking sure it is properly seated into place.Use buffer (B) to properly seat the ring intothe slider.

FIG. 16Lubricate the dust seals (15) and fit theminto the stanchions from the spring end.

VALVE AND PUMPING RODASSEMBLYFIG. 17After having overhauled or replaced thevalve unit and after having cleaned theinside of the tube, reassemble. Assemblevalve components, in correct sequence:washer (12), valve (29) and pocket (30).Then fit pumping rod (10) with seal ring (9)and rebound spring (11) into the valveassembly.

1615

10

12

29

30

11

9

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FIG. 18Lubricate O-rings (27) and (26) and reas-semble the foot buffer (14) onto the endpart of pumping rod (10).

FIG. 19Fit this assembly into the stanchion tube andproperly seat the valve assembly (D).Insert the stop ring (13).

CROWN AND STANCHIONSASSEMBLYFIG. 20Fit the crown and stanchions assembly (1)- with the dust seals in place - gently into thesliders seals.

WARNING: to avoid any damagesto sealing surfaces, keep the

stanchions duly lubricated and squaredinto the sliders.Press the crown and stanchions assemblyfully down and check that threaded ends ofpumping elements (10) are coming outthrough the bottom of the sliders.Check to see that the stanchions slide unre-stricted by cycling the fork up and downseveral times.The tube should slide freely inside the sealassembly without any side play. In the eventit is too hard or too soft, repeat the previoussteps described above and check compo-nents to ensure they are not damaged.Seat the dust seals (15) on top of thesliders.

27

14 10

26

13

D1

15 15

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FIG. 21Screw the foot nut (22) onto the pumpingrod threaded end (10).Tighten to 11 Nm.Check to verify that the stanchions slideproperly through the stroke by pumpingthem up and down several times.

HOW TO FILL WITH OILFIG. 22Pour oil little by little when the stanchionsare fully down and then pump with thecrown so as to have a better filling.Check that the oil level (H) is as required inboth legs.

SPRING AND CAPFIG. 23Fit the spring (8) and lower washer (33)into each stanchion tube.

22

Nm11

H

Travel (mm) H (mm)

110 60130 60

8

33

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FIG. 24Lubricate the O-ring (5) on the cap (4).Turn the preload adjuster (31) counter-clockwise until it is at its minimum setting(see section ADJUSTMENT).Start the complete cap assembly into thestanchion tube thread by hand. Tighten thecap (4) to 20 Nm.Set spring preload as specified in sectionADJUSTMENT.

4

5

Nm20

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SPECIFIC TOOLS

Ref. Item. Description and use A R 5089 AB Slider protector: to remove the oil seal from the slider B R 5090 Oil seal press: to press oil seal into the slider C R 5085 Hexagon wrench: to set rebound adjuster

A

CB