Table of Contents
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INSTRUCTIONS
GENERAL RULES
1. Where specified, assemble and disas-
semble the shock absorption system us-
ing the M
ARZOCCHI
M
2. On reassembling the suspension system,
always use new seals.
A
3. Clean all metal parts with a special,
preferably biodegradable solvent, such
R
as trichloroethane or trichloroethylene.
4. Before reassembling, lubricate all parts
A
in contact with each other using silicone
fat spray or a specific oil for seals.
T
5. Always grease the lip seal rings before
H
reassembling.
6. Use wrenches with metric size only.
O
Wrenches with inch size might damage
the fastening devices even when their
N
size is similar to that of the wrenches in
metric size.
special tools only.
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Table of Contents
Related Manuals for Marzocchi MARATHON
Summary of Contents for Marzocchi MARATHON
- Page 1 INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disas- semble the shock absorption system us- ing the M special tools only. ARZOCCHI 2. On reassembling the suspension system, always use new seals. 3. Clean all metal parts with a special, preferably biodegradable solvent, such as trichloroethane or trichloroethylene.
- Page 2 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 Oil leaking through the top of the slider 1.
- Page 3 In order to achieve best results, we absolutely forbidden to remove the original recommend to check and clean the area bolts (ref. B). In case of a Marathon S fork WARNING: steer tube/headset below the dust seal and the stanchion tube...
- Page 4 ADJUSTMENTS FORK LEG PRESSURIZATION IMPORTANT: inflate using the special REBOUND ADJUSTMENT Pump air through the valves to set COM- pump with the proper pressure (r.h. fork leg) ARZOCCHI PRESSION damping, as indicated in the gauge. Use of improper tools or other The right fork leg is equipped with an figure.
- Page 5 Pos. 3: “Minimum rebound NEGATIVE AIR CARTRIDGE ADJUST- IMPORTANT: inflate using the special damping” MENT (LH fork leg – valve is pump with the proper ARZOCCHI Turn the knob completely clockwise until located in the center of the cap) pressure gauge. Use of improper tools or hearing the last click.
- Page 6 DISASSEMBLY GENERAL – 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.
- Page 7 REMOVING UPPER CAP FIG. 2 (only right leg) FIG. 3 FIG. 1 Remove the RH cartridge circlip (27) with Unscrew the caps (30) and (33) complete (r.h. fork leg) a small screwdriver. with O-ring (24) with a 21-mm socket Undo screw (29) with an Allen wrench and Remove and keep the pin (26) and counter wrench.
- Page 8 FIG. 4 (only left leg) FIG. 5 REMOVING CARTRIDGES Lock the rod (16) and remove the cap (33) Push the stanchions (23) into the sliders (3) FIG. 6 from hydraulic cartridge end (22). and let all the oil drain out from the fork legs. Turn the fork leg upside-down and unscrew If this operation proves difficult, vice the rod Pump the stanchions several times to help...
- Page 9 FIG. 7 (only right leg) FIG. 8 (only left leg) FIG. 9 Pull the hydraulic cartridge (5) out of the Pull the air-operated cartridge (22) out of Withdraw the crown and stanchions as- R.H. stanchion tube. the L.H. stanchion tube. sembly (23) from the sliders (3).
- Page 10 REMOVING GUIDE BUSHING FIG. 11 FIG. 12 AND SEAL ASSEMBLY Remove the stop ring (9) from the sliders by Fit the slider protector (A) onto the slider FIG. 10 placing the screwdriver bit in one of the and remove the oil seal (8) with the help of Remove the dust seal (10) from the top of three openings on the stop ring.
- Page 11 FIG. 13 FIG. 14 REPLACING AIR VALVE Remove the upper washer (7) from the Fit the bit of a small screwdriver into upper FIG. 15 slider. edge slot of the pilot bushing (6) and lift This operation can be performed when fork gently.
- Page 12 AIR-OPERATED CARTRIDGE FIG. 17 OVERHAUL With a small screwdriver, remove the seal FIG. 16 (19) and the O-rings (18) from the rod Hold cartridge (22) and undo the ring nut body (16). Lubricate the O-rings before (14) and the O-ring (15) with a hex. reassembly.
- Page 13 REASSEMBLY CAUTION: before reassembling, all metal PILOT BUSHING AND SEAL FIG. 20 components should be washed carefully ASSEMBLY Fit the upper washer (7) into the slider so with inflammable, preferably biodegrad- FIG. 19 that it touches the pilot bushing. able, solvent and dried with compressed Check that no dirt or debris is between air.
- Page 14 FIG. 21 FIG. 22 FIG. 23 Lubricate the oil seal (8) and place it onto Insert the stop ring (9) into the slider making Lubricate the dust seals (10) and fit them the seal press (B) with the hollow side sure it is properly seated into place.
- Page 15 CROWN AND STANCHIONS REASSEMBLING CARTRIDGES FIG. 26 ASSEMBLY FIG. 25 Lubricate O-Rings (1) on the foot nuts (2) FIG. 24 Push the stanchions up to slider bottom and and screw them onto the cartridge (5) and Fit the crown and stanchions assembly (23) slightly grease O-ring (4), then fit it on (22) threaded ends.
- Page 16 Check that the oil quantity (Q) inside the Inflate as described in ADJUSTMENT sec- fork legs corresponds to the value indicated tion. in the table. Q(cc) Fork Travel (mm) (cc) model Marathon Marathon 29"...
- Page 17 FIG. 30 FIG. 31 Fit circlip (27) of the adjustment knob (r.h. fork leg) support and check for the proper position in Fit knob (28) and fully tighten the bolt (29) the seat. Fit also spring (25) and pin (26). to the recommended torque.
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