Table of Contents
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INSTRUCTIONS
General RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing M
ARZOCCHI
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 the
point it is well tightened, then tighten the
second screw and then go back to the
first one and screw it tighter.
4. Clean all metal parts with a special,
preferably biodegradable solvent, such
Monster
as trichloroethane or trichloroethylene.
5. Before reassembling, lubricate all parts
T
in contact with each other using silicone
fat spray or a specific oil for oil seals.
6. Always grease the conic seal rings be-
fore reassembling.
7. Use wrenches with metric size only.
Wrenches with inch size might damage
the fastening devices even when their
size is similar to that of the wrenches in
metric size.
special tools only.
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Table of Contents
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Summary of Contents for Marzocchi Monster T
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing M special tools only. ARZOCCHI 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.
- Page 2 FAILURES, CAUSES AND REMEDIES This paragraph reports some troubles 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. FAILURES CAUSES REMEDIES Excessive oil build up on stanchions 1.
- Page 3 RECOMMENDATIONS FOR INSTALLATION MAINTENANCE Installing the fork on a bicycle is a very MOUNTING THE FORK delicate operation that should be carried ON THE FRAME forks are based on advanced ARZOCCHI out with extreme care. FIG. A technology, supported by year-long experi- A threadless steer tube is pre-installed on Remove the upper crown (28) from steer ence in the field of professional mountain...
- Page 4 FIG. B FIG. C FIG. D Assemble the fork to the frame complete The stanchions edge (13) must be aligned Fit the handlebar support and the “A-Head with headset. Fit the upper crown (28) into with or slightly lower than the upper crown Set”...
- Page 5 FIG. E FIG. F If the crown (26) position with respect to Tighten the 4 stanchions fastening screws the stanchions (13) has been changed for (27) onto the crown to 11 Nm. any reason, adjust the original distance. – Distance “H” between crown and tyre WARNING: do not overtighten the edge (when inflated) should not be lower screws holding the stanchions to the...
- Page 6 FRONT WHEEL FIXING FIG. H FIG. I Tighten the wheel shaft (23) counter clock- Compress the fork several times so the IMPORTANT: for a safe and proper per- wise from the opposite end with a 8-mm sliders will become properly seated onto formance of this fork and all related de- Allen wrench.
- Page 7 DISC BRAKE SYSTEM ASSEMBLY FORK CONFIGURATION FOR 3" Assembling the brake caliper onto the slider WHEEL INSTALLATION is a very delicate operation that should be (Fig. L) carried out with extreme care. Improper Before you can install a 3" wheel, you will assembly might overstress the caliper sup- need to: ports, which might break.
- Page 8 ADJUSTMENTS SPRING PRELOAD REBOUND DAMPING ADJUSTMENT The spring preload for COMPRESSION Fork legs feature an adjuster (E) for RE- damping can be adjusted by turning the BOUND DAMPING adjustment. Turning knob (2) on top of fork legs. From the this adjuster clockwise into the cartridge factory the fork is set at minimum preload, rod, changes the hydraulic setting of the i.e.
- Page 9 DISASSEMBLY GENERAL – The reference numbers given in this section relate to the components shown in the forks exploded view. – These operations refer to the fork legs having already been removed from the crown and disassembled from the brake arch. –...
- Page 10 SPRING CHANGE FIG. 2 FIG. 3 FIG. 1 Remove the stop ring (4) from the top of the Place the stanchion tube in a vice. Be sure Set knob (2) to minimum preload value. preload knob support with a small screw- not to damage or dent it in the process.
- Page 11 FIG. 4 FIG. 5 HYDRAULIC CARTRIDGE CHANGE Position the plunger (7, see exploded view), Remove the upper washer (8), the preload FIG. 6 into the cap, to the minimum preload value. sleeve (1) and the spring (9). Let all the oil drain out. Push down the stanchion tube.
- Page 12 FIG. 7 GUIDE BUSHINGS AND SEAL FIG. 9 Pull the hydraulic cartridge (11) complete ASSEMBLY CHANGE Pull the stanchion tube (13) completely out with lower washer (46) and rebound spring FIG. 8 of the slider. (12) out of the stanchion tube. Use a small screwdriver and remove the Pull strongly to overcome the resistance of Replace the whole hydraulic cartridge.
- Page 13 FIG. 10 FIG. 11 FIG. 12 A sleeve (33) is located inside the stan- Remove the stop ring (15) from the slider Fit the slider protector (A) onto the slider chion tube. Remove the outer snap ring by placing the screwdriver bit in one of the and remove the oil seal (16) with the help (32) to remove the sleeve (33).
- Page 14 FIG. 13 FIG. 14 Remove the upper washer (17) from the To remove the guide bushing (18), beat slider. powerfully the slider edge on a wooden surface. Perform this operation with ex- treme care and try to keep the slider perpen- dicular to the wooden surface.
- Page 15 REASSEMBLY CAUTION: before reassembling, all metal FIG. 16 FIG. 17 components should be washed carefully Stick some adhesive tape onto the stan- Insert the bit of the flat screwdriver into the with inflammable and biodegradable sol- chion bottom (13) to protect it. Insert the oil guide bushing slot (34) to fit it on the vent and dried with compressed air.
- Page 16 FIG. 18 FIG. 19 FIG. 20 Gently insert the stanchion tube (13) into Press the oil seal (16) into place until it Insert the stop ring (15) making sure it is the slider from the bushing side. touches the lower washer (17) by using the properly seated into place.
- Page 17 FIG. 21 HYDRAULIC CARTRIDGE FIG. 23 Lubricate the dust seal (14) and insert it into FIG. 22 Grease the O-ring (21) on the foot nut (22) the top of the slider. Fit the rebound spring (12) and the lower and screw the nut onto the hydraulic car- Fit it into the slider seat.
- Page 18 HOW TO FILL WITH OIL SPRING AND CAP FIG. 26 FIG. 24 FIG. 25 Position the plunger (7, see exploded view), Pour the oil little by little when the stanchion Fit the spring (9), the preload sleeve (1) into the cap, to the minimum preload value. tube is fully down and then pump the and the upper washer (8) into the stanchion Screw the complete plug (5) fully onto the...
- Page 19 FIG. 27 FIG. 28 FIG. 29 Lift the stanchion tube and fit the plug (5) by Fit the stop ring (4) of the preload knob Fit the preload knob (2), secure it on the hand. Place the stanchion tube in vice. support and make sure it is fitted properly support and tighten the Allen bolt (3) to 1.5 Make sure not to damage or squeeze it.
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