Marzocchi Jr. T QR20 Instructions Manual
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Marzocchi Jr. T QR20 Instructions Manual

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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
Jr. T
as trichloroethane or trichloroethylene.
5. Before reassembling, lubricate all parts
QR20
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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Summary of Contents for Marzocchi Jr. T QR20

  • 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

    FAILURES, CAUSES AND REMEDIES This 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. FAILURES CAUSES REMEDIES Excessive oil build up on stanchions 1.

  • Page 3: Recommendations For Maintenance

    RECOMMENDATIONS FOR MAINTENANCE forks are based on advanced ARZOCCHI technology, supported by year-long experi- ence in the field of professional mountain biking. In order to achieve best results, we recommend to check and clean the area below the dust seal and the stanchion tube after each use and lubricate with silicone oil.

  • Page 4: Installation

    INSTALLATION Installing the fork on a bicycle is a very MOUNTING THE FORK ON THE FIG. B delicate operation that should be carried FRAME Assemble the fork to the frame complete out with extreme care. The installation should FIG. A with headset.
  • Page 5 FIG. C FIG. D FIG. E The stanchions edge (28) must be aligned Fit the handlebar support and the “A-Head If the crown (13) position with respect to with or slightly lower than the upper crown Set” plug over the upper crown (1) and the stanchions (28) has been changed for (1).

  • Page 6: Front Wheel Assembly

    FIG. F FRONT WHEEL ASSEMBLY DISC BRAKE SYSTEM ASSEMBLY Tighten the 4 stanchions fastening screws Assembling the brake caliper onto the slider IMPORTANT: fixing the front wheel prop- (15) onto the crown to 11 Nm. is a very delicate operation that should be erly as specified in the instructions given carried out with extreme care.

  • Page 7: Spring Preload

    ADJUSTMENT SPRING PRELOAD REBOUND DAMPING ADJUSTMENT Spring preload can be adjusted by turning The adjuster controlling REBOUND damp- the knob (2) on the top of the fork legs. From ing adjustment is accommodated inside the factory the fork is set at minimum preload, cartridge rod (27) inside each fork leg.

  • Page 8: Disassembly Diagram

    DISASSEMBLY GENERAL – 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. 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.
  • Page 9 SPRING CHANGE FIG. 2 GUIDE BUSHING AND FIG. 1 Push the stanchion tube into the slider and SEAL ASSEMBLY CHANGE Place the stanchion tube (28) in a vice. Be remove the upper washer (9), the preload FIG. 3 sure not to damage or squeeze stanchion in sleeve (16), the spring (17), the retaining Let all the oil drain out.
  • Page 10 GUIDE BUSHING AND SEAL FIG. 5 FIG. 6 ASSEMBLY CHANGE Remove the dust seal (19) from the top of Remove the stop ring (20) from the sliders FIG. 4 the sliders using a small screwdriver. by placing the screwdriver bit in one of the Pull the stanchion tube (28) completely out three openings on the stop ring.
  • Page 11 FIG. 7 FIG. 8 FIG. 9 Fit the slider protector (A) onto the slider Remove the upper washer (22) from the Fit the bit of a small screwdriver into upper and remove the oil seal (21) with the help slider. edge slot of the pilot bushing (23) and lift of a large screwdriver.
  • Page 12 REPLACING PUMPING ELEMENT VALVE ASSEMBLY CHANGE SEALS FIG. 11 FIG. 10 To check that the valve assembly is operat- Remove the foot buffer (31) complete with ing correctly, it is necessary to work on the ring (32) from the pumping rod (27) end. inside of the stanchion tube.
  • Page 13 REASSEMBLY FIG. 14 FIG. 13 CAUTION: before reassembling, all metal Lubricate the oil seal (21) and place it onto Fit the upper washer (22) into the slider so components should be washed carefully the seal press (B) with the hollow side that it touches the pilot bushing.
  • Page 14 FIG. 15 FIG. 16 VALVE AND PUMPING ROD Insert the stop ring (20) into the slider Lubricate the dust seals (19) and fit them ASSEMBLY making sure it is properly seated into place. into the stanchions from the spring end. FIG.
  • Page 15 FIG. 18 FIG. 19 STANCHION TUBE ASSEMBLY Lubricate O-rings(25) and (32) and reas- Fit this assembly into the stanchion tube and FIG. 20 semble the foot buffer (31) onto the end properly seat the valve assembly (D). Fit the stanchion tube (28) gently into the oil part of pumping rod (27).
  • Page 16 FIG. 21 HOW TO FILL WITH OIL SPRING AND PRELOAD CAP Screw the foot nut (39) onto pumping FIG. 22 FIG. 23 element thread (27). Pour the oil little by little when the stan- Fit the spring (37), the retaining spring cap Tighten to 11 Nm.
  • Page 17 FIG. 24 FIG. 25 Fit the preload sleeve (16) and the top Lubricate the O-ring (6) on the cap (5). washer (9) into the stanchions. Turn the plunger (8, see exploded view) inside the cap counterclockwise until it is at its minimum setting.

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