Super TQR20

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. If two screws are close one to the other,always tighten using a 1-2-1 sequence.In short, screw the first screw just up to thepoint it is well tightened, then tighten thesecond screw and then go back to thefirst one and screw it tighter.

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

5. Before reassembling, lubricate all partsin contact with each other using siliconefat spray.

6. Always grease the conic seal rings be-fore reassembling.

7. 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.

INSTRUCTIONS

Super TQR20

FAILURES, CAUSES AND REMEDIESThis paragraph reports some troubles 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.

Oil leaking through the bottom of slider O-ring seal on the cartridge nut is damaged Replace the O-ring seal

Excessive oil build up on stanchions 1. Oil seal is worn out2. Stanchion tube is scored3. Excessive dirt on slider oil seal

1. Replace oil seal2. Replace stanchion tube, oil seal and dust

seal3. Clean the oil seal seat and replace oil

seal

Fork has not been used for some time andis locked out

Oil seals and dust seals tend to stick tostanchion tube

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

Fork rebounds too fast even though theadjuster is set to hardest damping position

Cartridge is faulty Replace hydraulic cartridge

Excessive play of stanchions into the sliders Main slider bushings are worn Replace main slider bushings

FAILURES CAUSES REMEDIES

Adjuster position does not affect fork opera-tion

Dirt inside legs Clean carefully and change oil

Super TQR20

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.

MOUNTING THE FORK ON THEFRAMEFIG. ARemove the upper crown (1) from steertube and fork legs by loosening the 3fastening bolts (11).

1

11

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.

Super TQR20

FIG. BAssemble the fork to the frame completewith headset. Fit the upper crown (1) intothe stanchions and the steer tube.

1

FIG. CThe stanchions edge (28) must be alignedwith or slightly lower than the upper crown(1).If fork legs overprotrude, fit some spacers(C) to the plate close to the steer tube.

1C

28

FIG. DFit the handlebar support and the A-HeadSet cap over the upper crown (1) and thenadjust the steering.Now finally tighten the 3 bolts (11) on theupper crown to 11 Nm.

WARNING: Loosen the 3 screws(11) on the upper crown before

adjusting the steering. Tighten the abovebolts to the specified torque when finished.

11

1

Nm11

Super TQR20

FIG. FTighten the 4 stanchions (28) fasteningscrews (15) onto the crown to 11 Nm.

WARNING: do not overtighten thescrews holding the stanchions to the

crown as this may distort the stanchions andweaken the whole structure.

After any installation always check for theproper torque of screws fastening stan-chion tube onto lower crown and on uppercrown.

15

28

Nm11

FIG. EIf the crown (13) position with respect tothe stanchions (28) has been changed forany reason, adjust the original distance.– Distance “H” between crown and tyre

edge (when inflated) should not be lowerthan total travel (170 mm) + 3 mm.

WARNING: if lower Crown is im-properly matched with stanchions, it

may touch the tyre and cause severe inju-ries to the rider.

H28 2813

Super TQR20

DISC BRAKE SYSTEM ASSEMBLYAssembling 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.

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.

Nm6

B D

B

C

A

A

C

Super TQR20

ADJUSTMENTSSPRING PRELOADThe spring preload for COMPRESSIONdamping can be adjusted by turning theknob (2) on top of fork legs. From thefactory the From the factory the fork is set atminimum preload, i.e. the adjustment knobcompletely unscrewed counterclockwise.However, the springs are slightly preload-ed to help counteract static loads. By turn-ing the adjustment knob clockwise, thepreload is increased up to the maximumvalue equal to 15 mm of spring preload.This adjustment is essential in order to havethe right fork response for the rider’s weightand riding style.

REBOUND DAMPING ADJUSTMENTThe fork legs feature an adjuster (C) forREBOUND damping adjustment. Turningthis adjuster clockwise into the cartridgerod, changes the hydraulic setting of theinner valves. In short, the amount of adjust-ment applied on the piston in the fluiddetermines the rate of compression damp-ing.To adjust, always start from the minimumdamping setting, i.e. unscrew completelycounterclockwise. About 8 turns - abt. 4 mmof the adjustment - are possible.

2 C

Super TQR20

DISASSEMBLYGENERAL– The reference numbers given in this section relate to the components shown in the fork exploded view.– Operations refer to the fork legs already removed from the upper crown and from the crown.– Before starting any operation. please read the diagram below. It shows the quickest procedure and the exact disassembling sequence.

Start from the part to be disassembled and then follow the arrows to remove the other parts.

DISASSEMBLY DIAGRAM

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STOP RING FIG. 2

STANCHION TUBE FIG. 8

DUST SEAL FIG. 9SPRING FIG. 5

PRELOAD KNOB FIG. 1

HYDRAULICCARTRIDGE CHANGE

FOOT NUT FIG. 6

HYDRAULIC CARTRIDGE FIG. 7

GUIDE BUSHING ANDSEAL ASSEMBLY CHANGE

OIL SEAL FIG. 11

UPPER WASHER FIG. 12

GUIDE BUSHING FIG. 13

STANCHION TUBE CAP FIG. 3/4

SPRING CHANGE

STOP RING FIG. 10FORK OIL CHANGE

Super TQR20

SPRING CHANGEFIG. 1Set the knob (2) to the minimum preloadposition.Loosen the grub screw (3) fastening thepreload knob (2) by means of a 1.5 mmAllen wrench. Remove grub screw from capassembly.

FIG. 2Remove the stop ring (4) from the top of thepreload knob support with a small screw-driver.

FIG. 3Place the stanchion tube in a vice. Be surenot to damage or squeeze stanchion in theprocess. Unscrew the plugs (5) with a 26mm hexagon wrench.Remove the plugs complete with theO-ring (6) from the stanchions.

23

45 6

Super TQR20

FIG. 4Unscrew the cap (5) from the cartridge(21) rod.

5

21

10

37

8

9

8

35

34

FIG. 5Push the stanchion tube into the slider andremove the top washer (8), the preloadsleeve (9), the spring (10), the secondwasher (8) and the other spring (37).Let all the oil drain into the fork leg.By following this procedure, there is noneed to check the oil level.Make all necessary changes.

HYDRAULIC CARTRIDGE CHANGEFIG. 6Let all the oil drain out.

WARNING: Remember to alwaysrecycle any used oil.

To change the fork leg oil follow the proce-dure as described in section “REASSEMBLY”from FIG. 22 to FIG. 27.Turn the fork leg upside-down and unscrewthe foot nut (35) complete with O-ring (34)by the use of a 15 mm socket wrench.

Super TQR20

FIG. 7Pull the hydraulic cartridge (21) completewith foot washer (36, see exploded view)out of the stanchion tube.Replace the whole hydraulic cartridge.

21

28

27

22

GUIDE BUSHING AND SEALASSEMBLY CHANGEFIG. 8Pull the stanchion tube (28) completely outof the slider (27).

FIG. 9Use a small screwdriver and remove thedust seal (22) from slider top.

Super TQR20

FIG. 10Remove the stop ring (23) from the sliderby placing the screwdriver bit in one of thethree openings on the stop ring and care-fully lifting the ring out of place.

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

FIG. 11Fit the slider protector (A) onto the sliderand remove the oil seal (24) with the helpof a large slot screwdriver.

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

FIG. 12Remove the upper washer (25) from theslider.

2324

A

25

Super TQR20

FIG. 13Fit the bit of a small screwdriver into theupper edge slot of the guide bushing (26)and lift gently. Pull the bushing out of theslider and make all necessary changes.

26

Super TQR20

26

25

REASSEMBLYCAUTION: before reassembling, all metalcomponents should be washed carefullywith inflammable and biodegradable sol-vent and dried with compressed air.

GUIDE BUSHING AND SEALASSEMBLYFIG. 14Check that no dirt or debris is betweenslider and bushing. Insert the guide bushing(26) into place so that it adheres to theslider.

FIG. 15Fit the upper washer (25) into the slider sothat it touches the guide bushing.

FIG. 16Lubricate the oil seal (24) and place it ontothe seal press (B) with the hollow sidetoward the slider.Press the oil seal into place until it touchesthe lower washer by using the above sealpress.

24

B

Super TQR20

2322

FIG. 17Insert the stop ring (23) into the slidermaking sure it is properly seated into place.Use buffer (B) to properly seat the ring intothe slider.

FIG. 18Lubricate the dust seal (22) and fit it into thestanchion from the spring end.

FIG. 19Fit the stanchion tube (28) gently into the oilseal (24), together with dust seals.Rotate the stanchion tube while inserting itinto the seal to reduce the chance of dam-aging the seals.Turn the slider over and check that cartridgethread (21) is sticking out through the sliderhole.Check to see that the stanchion tube slidesunrestricted by cycling the fork up anddown several times.The tube should slide freely inside the sealassembly without any side play.In the event it is too hard or too soft, repeatthe previous steps described above andcheck components to ensure they are notdamaged.Seat the dust seal (22) on top of the slider.

28

22

Super TQR20

21

35

34

Nm11

HYDRAULIC CARTRIDGEFIG. 20Insert washer (36, see exploded view)together with the complete hydraulic car-tridge (21) with the stanchion pressed fullydown into the slider.

FIG. 21Grease the O-ring (34) on the foot nut (35)and screw the nut on the hydraulic cartridgethreaded end.Tighten to 11 Nm.Pump stanchion up and down several timesto make sure it slides properly through thestroke.

HOW TO FILL WITH OILFIG. 22Pour the oil little by little when the stanchiontube is fully down and then pump with thecartridge (21) rod so as to have a betterfilling.Cartridge is full when no air is detectedwhen pumping, in the fully compressedposition.Check that the oil level is 80 mm from thetop of the stanchion tube in each leg.

80

21

Super TQR20

9

816

10

37

8 5

6

21

18

SPRING AND CAPFIG. 23Fit the spring (37), the washer (8), thespring (10), the preload sleeve (9) and thetop washer (8) into the stanchion tube.Lubricate the O-ring (16) on the top of thepreload knob support and the O-ring (6) onthe cap (5).

FIG. 24Move the plunger (7, see exploded view),in the cap, to the minimum preload posi-tion.Screw the complete cap (5) onto the car-tridge (21) rod.Screw cap all the way in.Tighten check nut (18) against cap (5).

FIG. 25Take out stanchions and fit caps (5) byhand.Place the stanchions in a vice making surethey are not damaged or dented and tightenthe caps to 20 Nm.

5

Nm20

Super TQR20

FIG. 26Fit the stop ring (4) of the preload knobsupport and make sure it is properly seatedinto place.

FIG. 27Fit the preload knob (2) and secure it on thesupport by tightening the grub screw (3) to1.5 Nm.Install fork legs into crown and upper crownas specified in section “INSTALLATION”.

4

Nm1,52

3

indice: grafica1: avanti: stampa: help: indietro: