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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. Alwaysrefer to this table before doing any repair work.

Adjuster position does not affect fork opera-tion

1. Dirt inside legs2. O-ring into pumping element damaged.

1. Clean carefully and change oil2. Replace O-ring.

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

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

Oil leaking through the bottom of slider O-rings at pumping element bottom andadjusting rod damaged.

Replace the O-rings

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

1. Replace oil seal2. Replace crown/stanchions assembly, oil

seals and dust seals3. Clean the oil seal seat and replace oil seal

FAILURES CAUSES REMEDIES

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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.

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Nm6

B D

B

C

A

A

C

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.

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.

FRONT WHEEL ASSEMBLYIMPORTANT: fixing the front wheel prop-erly as specified in the instructions givenbelow is essential for the proper operationof this fork and all related devices, andtherefore for safe riding. You are advised tofollow these instructions closely.Slacken the lock nut of the quick releaselever so the hub will fit between the forksliders.Make sure the quick release bushings (A)are centered to the recesses in the sliders.

Lock the quick release lever (B) and makesure the bushings (A) are properly seatedin the sliders.Fit bolt end (C) in suitable slider groove andtighten the screw (D) to specified torque.

WARNING: These sliders are spe-cifically designed to fit this type of

hub. Do not use any hub design other thanthat specified here, as this would not ensureproper fastening of the wheel and may leadto breakdown of the assembly components.

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2C

ADJUSTMENTSPRING PRELOADSpring preload determines COMPRESSIONdamping and is adjusted by turning theadjustment knob (2) 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.

REBOUND ADJUSTMENT(only right leg)Each fork leg is equipped with an adjusterscrew (C) for REBOUND damping at sliderbottom.To adjust, always start from the minimumdamping setting, i.e. with the screw fullyturned counterclockwise. Each adjustingposition can be identified by a click.

IMPORTANT: do not force the adjusterknob (C) over its limit.

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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

CHANGING PUMPINGELEMENT SEALS

FOOT NUT FIG. 4SPRING FIG. 2

DUST SEAL FIG. 6

STOP RING. 7

OIL SEAL FIG. 8

PUMPING ROD FIG. 12

REBOUND SPRING FIG. 12

VALVE ASSEMBLYCHANGE

PILOT BUSHING ANDSEAL ASSEMBLY CHANGE

STANCHION TUBE CAP FIG. 1

FOOT BUFFER FIG. 11

CROWN AND STANCHIONSASSEMBLY FIG. 5

SPRING CHANGE

BOTTOM ADJUSTER FIG. 3

PUMPING ELEMENT INNER O-RINGFIG. 13

STOP RING FIG. 14UPPER WASHER FIG. 9

PILOT BUSHING FIG. 10 VALVE ASSEMBLY FIG. 14

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SPRING CHANGEFIG. 1Unscrew the caps (5) with a 21 mm socketwrench.Remove the caps complete with O-ring (6)from the stanchions.

FIG. 2Push the stanchions into the sliders andremove the lower washer (11) and thespring (34) 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. 27 to Fig. 29.

PILOT BUSHING AND SEALASSEMBLY CHANGEFIG. 3 (only right leg)Turn fork legs upside down and pressadjuster retainer (28) with a small screw-driver to release it.Remove adjuster assembly (28) from theslider.

5

6

28

34

11

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1

FIG. 4Remove foot nuts (26) and (29) with asocket wrench.

FIG. 5Withdraw the crown and stanchions as-sembly (1) from the sliders.

FIG. 6Remove the dust seal (19) from the top ofthe sliders using a small screwdriver.

19

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FIG. 7Remove the stop ring (20) 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.

FIG. 8Fit the slider protector (A) onto the sliderand remove the oil seal (21) 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. 9Remove the upper washer (22) from theslider.

2021

A

22

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23

1825 14

4225 12

Sx.

Dx.

13

15

14 12

FIG. 10Fit the bit of a small screwdriver into upperedge slot of the pilot bushing (23) and liftgently. Pull the bushing out of the slider andmake all necessary changes.

REPLACING PUMPING ELEMENTSEALSFIG. 11Remove the foot buffer (18) and (42)complete with ring (25) from the pumpingrod ends (14) and (12).

FIG. 12Withdraw the pumping elements (14) and(12) and the rebound spring (15) from thestanchion tube top.Replace the seal ring (13) if damaged orworn out.

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27

14

A

3317

40 39 35 16

FIG. 13 (only right leg)Remove the stop ring (33) from pumpingelement bottom (14) with a small flat screw-driver.Mark stop ring seat into inner rod for properfitting.Use the same screwdriver to remove thering (A) and screw inner rod until adjusterthreaded end is disengaged from pumpingelement.Remove inner rod and replace O-ring (27)if damaged.

VALVE ASSEMBLY CHANGE(only right leg)FIG. 14To 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 (17) using pointedpliers.Pull the valve assembly out of the stanchionwith one finger in the following order:pocket (40), valve (39) rebound spring(35) and washer (16).

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23

22

21

B

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

PILOT BUSHING AND SEALASSEMBLYFIG. 15Check that no dirt or debris is betweenslider and bushing. Insert the pilot bushing(23) into place so that it adheres to theslider.

FIG. 16Fit the upper washer (22) into the slider sothat it touches the pilot bushing.

FIG. 17Lubricate the oil seal (21) 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.

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20 19

33

14

A

27

FIG. 18Insert the stop ring (20) into the slidermaking sure it is properly seated into place.Use buffer (B) to properly seat the ring intothe slider.

FIG. 19Lubricate the dust seals (19) and fit theminto the stanchions from the spring end.

PUMPING ROD ASSEMBLYFIG. 20 (only right leg)Lubricate the O-ring (27) and fit inner rodthreaded end into pumping element (14).Turn inner rod clockwise so that threadedend can be seen the into pumping elementand stop ring seat (33), marked duringdisassembly.Fit stop ring (33) into inner rod seat.

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40

39

35

16 14

15

13

25

18 14

24

25

42 12

24

Dx.

Sx.

17

F

Dx.

VALVE AND PUMPING RODASSEMBLYFIG. 21 (only right leg)After having overhauled or replaced thevalve unit and after having cleaned theinside of the tube, reassemble.Assemble valve components, in correct se-quence: washer (16), rebound spring (35),valve (39) and pocket (40).Then fit pumping element (14) with sealring (13) and rebound spring (15) into thevalve assembly.

FIG. 22Lubricate the O-rings (24) and (25) andreassemble the foot buffer (18) onto pump-ing element end (14) and foot buffer (42)on pumping element top (12).

FIG. 23 (only right leg)Fit this assembly into the stanchion tube andproperly seat the valve assembly (F).Insert the stop ring (17).

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Sx.12

151

19 19

FIG. 24 (only left leg)Fit pumping element (12) from stanchiontop with rebound spring (15).

CROWN AND STANCHIONSASSEMBLYFIG. 25Fit the crown and stanchions assembly (1)- with the dust seals in place - gently into thesliders seals.IMPORTANT: to avoid any damages tosealing surfaces, keep the stanchions dulylubricated and squared into the sliders.Press the crown and stanchions assemblyfully down and check that threaded ends ofpumping elements (14) and (12) are com-ing out through 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 (19) on top of thesliders.

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FIG. 26Screw the foot nuts (26) and (29) on thethreaded elements of pumping elements(14) and (12).Tighten to 11 Nm.Check to verify that the stanchions slideproperly through the stroke by pumpingthem up and down several times.

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H

110

130

Lh.Rh.Lh.Rh.

55555040

Travel Leg H(mm) (mm)

HOW TO FILL WITH OILFIG. 28Pour 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 is H mm from the topof the stanchion tube, in both legs.

34

SPRING AND CAPFIG. 29Fit the springs (34) into each stanchiontube.

28 D E

FIG. 27Fit the retainer (D) into the slider (E) toreassemly the adjuster unit (28).

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5

6

FIG. 30Lubricate the O-ring (6) on the cap (5).Turn the preload adjuster (9) counterclock-wise until it is at its minimum setting andinstall the lower washer (11).Start the caps with the O-ring (6) in placeinto the stanchion tube threads by hand.Tighten caps (5) to 20 Nm.